The Effect of Vacuum on the Mechanical Properties of Sand Cast AA6061 Alloy

Daronde, Subodh; Kuthe, Abhaykumar M.; Keerti, Shishir; Khatirkar, Rajesh K.; Bagde, Ashutosh; Kamble, Manish; Dahake, Sandeep W.

doi:10.1007/s11665-021-06154-9

Cited by 9 publications

(3 citation statements)

References 49 publications

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“…Extrusion molding [ 9 ], which utilizes an extruder [ 10 ], involves thoroughly mixing and heating plastic fiber or sheet-like polymer raw materials to form sheets. These molten sheets or film materials are then continuously heated and vacuum-formed through aluminum alloy molds [ 11 ] or shaping modules [ 12 ], followed by cooling and cutting to produce various products. The process [ 13 ] is illustrated in Figure 1 .…”

Section: Introductionmentioning

confidence: 99%

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Chen,

Huang

2024

Polymers

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This research investigates the control of thickness and weight in plastic extrusion vacuum-thermoforming products to identify optimal key parameters for cost reduction and energy savings. The initial step involves identifying crucial influencing factors. In this step, the Delphi technique was employed through a questionnaire administered to a panel of expert scholars to ensure minimal error and maximal reliability in determining key influencing factors. Consensus was sought to establish appropriateness and consistency. Subsequently, the Taguchi method was applied for quality design and planning of the extrusion vacuum-forming process. The experimental design parameters were selected using an L18 (21 × 37) orthogonal array, and the desired quality characteristics were determined. Comparative analysis of quantitative production data from two consecutive experiments was conducted, and based on F-values and contribution analysis, the combination of control factors maximizing the Signal-to-Noise (S/N) ratio was identified. The objective is to seek optimal parameters for improving the quality of the plastic polypropylene (PP cup lid) manufacturing process, reducing process variability, and identifying the most robust production conditions. Through multiple actual production prediction experiments, it was determined that five control factors, “polypropylene new material ratio,” “T-die lips adjustment thickness”, “mirror wheel temperature stability”, “molding vacuum pressure time”, and “forming mold area design”, contribute to the maximization of the S/N ratio, i.e., minimizing variability. Statistical validation confirms a significant improvement in product quality and weight control. Noteworthily, the quality control model and experimental design parameters established in this study are also applicable to other plastic products and bio-based materials, such as PET, HIPS, and biodegradable PLA lids with added calcium carbonate. The results of the experimental production demonstrate its ability to consistently control product weight within the range of 3.4 ± 0.1 g, approaching the specified tolerance limits. This capability results in approximately 2.6% cost savings in product weight, contributing significantly to achieving a company’s KPI goals for environmental conservation, energy efficiency, and operational cost reduction. Therefore, the findings of this study represent a substantial and tangible contribution.

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Section: Introductionmentioning

confidence: 99%

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Chen,

Huang

2024

Polymers

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“…Wang et al [6] found through their research on fatigue fracture of die-casting parts that 98.5% of fatigue crack sources in die-casting alloys originate from internal pores in the castings; Koch et al [7] have shown that the fatigue crack source of die-casting alloys is located at the edge of the void defect near the center of the specimen, and the crack grows outward during tension. After studying the relationship between internal defects and the casting performance of diecasting parts, Szalva et al [8][9] found that the differences in mechanical properties of die-casting parts are caused by different areas of high concentrations of gas pores in the specimens, and gas shrinkage is the main factor affecting the elongation of die-casting alloy. Easton et al [10] found that tensile fracture cracks are generated along grain boundaries, and they mostly occur near the surface defect zone of the casting.…”

Section: Introductionmentioning

confidence: 99%

Study of mechanical properties of the YL113 die casting surface and middle layer

Chen

2024

J. Phys.: Conf. Ser.

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The YL113 die casting surface and middle layer are separated by machining and densities, porosities and mechanical properties of the YL113 die casting surface and middle layer are measured. Results show that the densities and mechanical properties of the total YL113 die casts are in between those of the YL113 die casting surface and middle layer and are identical to those of the YL113 die casting middle layer. The porosities of the die casting surface layer are smaller and fewer and its densities are bigger and mechanical properties are better than those of the middle layer. Effects of different die casting process parameters on the surface layer and the middle layer of die casting are different, of whom effects of the casting pressure and the biscuit thickness on them are most obvious. The densities and mechanical properties of the surface layers and the middle layers of die castings increase with increasing the casting pressures and the biscuit thicknesses. In addition, the effects of densities on the mechanical properties of the die casting middle layers are more obvious than those of the die casting surface layer.

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“…In complex castings such as engine blocks and cylinder heads, numerous intricately shaped sand cores are employed. During the filling and solidification of molten metal, the sand cores are subjected to heating, causing the organic binder within them to decompose or burn at high temperatures, generating gas [1], [2]. If the gas cannot be expelled from the core and instead infiltrates the molten metal, it results in entrapped gas pores [3].…”

Section: Introductionmentioning

confidence: 99%

Research on Gas Pore Prediction Method Based on Sand Core Characteristic Time

Wang,

Wu,

Wang

et al. 2024

Proceedings of International Conference on Artificial Life and Robotics

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In the production of castings, gas pores are a prevalent defect, particularly in components where air-tightness is crucial, such as cylinder blocks and heads. These defects primarily arise from the intrusion of gases into the casting during the combustion of resin in the sand core. Due to the complexity of the sand core's gas evolution and venting process, predicting gas pores using numerical simulation poses significant computational and time challenges. This paper introduces a rapid prediction method for gas pores based on the characteristic time of the sand core. By setting the heat transfer boundaries, initial conditions, and termination criteria for computation, the thermal conductivity of the sand core is adjusted. The termination computation time is used as the characteristic time of the sand core. This time is then compared with a critical characteristic time to predict the distribution of gas pores. As the analysis of more sand cores is incorporated, the precision of the critical characteristic time improves, leading to more accurate predictions of gas pores in castings.

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The Effect of Vacuum on the Mechanical Properties of Sand Cast AA6061 Alloy

Cited by 9 publications

References 49 publications

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality

Study of mechanical properties of the YL113 die casting surface and middle layer

Research on Gas Pore Prediction Method Based on Sand Core Characteristic Time

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