UNIVERSITI TEKNOLOGI MALAYSIA FACULTY OF MECHANICAL ENGINEERING

SME 4912

FINAL YEAR PROJECT DRAFT 1

Title: Simulation of High Pressure Die Casting of Automotive Component using AnyCASTING Software

By JONATHAN NG SOON SEN Supervisor: Assoc. Prof. Hamidon Bin Musa

ii TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

INTRODUCTION 1.1 Project Background 1.2 Problem Statement 1.3 Objective of Study 1.4 Scope of Study

1 1 4 6 6

LITERATURE REVIEW
2.1 Introduction 2.2 Die Casting Machine 2.2.1 Clamping Unit 2.2.2 Die Assembly Unit 2.2.3 Injection Unit 2.2.3.1 Hot Chamber Process 2.2.3.2 Cold Chamber Process 2.3 Principal Variables that Affect Die Casting Quality 2.3.1 Pouring Temperature 2.3.2 Die Temperature 2.3.3 Shot Velocity 2.3.4 Solidification Time 2.4 Effect of Cooling Rate 2.5 Aluminum 2.6 Defects in Die Casting Process 2.6.1 Surface Defect 2.6.1.1 Cold Shut 2.6.1.2 Cracks 2.6.1.3 Drag 2.6.2 Internal Defects 2.6.2.1 Porosity 2.6.2.2 Solidification Shrinkage 2.6.2.3 Gas Entrapment 2.6.3 Dimensional Defects

7 7 9 10 11 14 14 15 16 17 18 19 20 21 21 23 24 24 24 25 25 25 26 26 26

iii
2.7 Modeling and Simulation of Casting 2.7.1 Casting modeling 2.7.2 Casting Simulation 2.8 Overall Evaluation Criterion 27 27 28 30

METHODOLOGY 3.1 Case Study and CAD Drawing 3.2 AnyCASTING Simulation 3.3 Casting Material Selection 3.4 The Process Parameter 3.5 Analysis Scope 3.5.1 Retained Melt Modulus 3.5.2 Secondary Dendrite Arm Spacing 3.5.3 Overall Evaluation Criterion Analysis 3.5.4 Weighting of Analysis Area

31 31 32 33 33 34 34 35 35 35

EXPERIMENTATION 4.1 Generate CAD Drawing 4.2 Runner, Gate and Overflow 4.3 Create Mesh of Model using AnyMesh 4.4 Set Constants and parameters into AnySolver

36 37 38 39 39

REFERENCES

42

iv LIST OF TABLES

TABLE NO.

TITLE

PAGE

1.1 2.1 2.2 2.3 2.5 2.6 2.7 2.8 2.9 3.1 3.2 4.1 4.2 4.3

Rejected quantity by defects Description of the typical casting cycle Description of the die Typical die life when casting various alloys Trouble shooting chart Thermal constant of major alloy group

5 8 11 13 17 18 20 23 28 34 35 39 40 40

Description of velocity of the stroke

Commonly used aluminum alloy in various casting processes Casting simulation software Analysis scope Weighting of Analysis Area Parameters and levels for analysis Design matrix Example of table for result simulation

v LIST OF FIGURES

FIGURE NO.

TITLE

PAGE

1.1

Traditional trial and error method in die casting process parameters determination

1.2 1.3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3.1 3.2 3.3 4.1 4.2 4.3

Power steering housing Chart of rejected quantity by defects Clamping unit Label of moving half and fixed half Schematic diagram of a hot chamber pressure die casting machine Schematic diagram of a cold chamber pressure die casting machine Variation of temperature in one cycle of a casting process The common graph if the shot velocity along the stroke Secondary dendrite arm spacing Actual picture of power steering housing CAD modeling of power steering housing Ischikawa diagram of casting dimensional stability Steps in experimentation 2D view of the power steering housing Model with gating system and overflow

4 5 10 11 15 16 19 19 20 31 32 33 37 38 38