Simulation of High Pressure Die Casting Process.

Vijay S 1, Dr. S.Nagaraja Rao2, Sri Rameshbabu K3 [1] M.Tech, Student,[2] Principal-PG Studies[3]Course co-ordinator,Govt. Tool Room & Training center, Mysore.

ABSTRACT High pressure die casting (HPDC) is an important process for manufacturing high volume and low cost automotive components. Liquid metal (generally aluminium) is injected at high speed (50 to 100 m/s) and under very high pressures through complex gate and runner systems and into the die. In mold filling of the Die casting process, defects such as miss run, cold shut, gas and oxide film entrapment, and shrinkage often occur. During molten metal pouring, gas in the mold is compressed by the melt and discharged outside through the vent in metallic mold casting such as die-cast. If the die casting method is not proper, such gas defects as miss run due to back pressure of the gas and gas entrapment occur. To eliminate these defects, Die casting methods are investigated through experience and experiments, but much development cost and a long development period are required, and recently, therefore, simulation has been increasingly used. For this reason, many studies on mold filling and solidification analysis in the die casting process have been conducted, and some commercial software such as Magma, ProCAST, Zcast, Novacast, 3D Flow, DieCAS, AutoCAST etc has been sold on the market and utilized as a tool for predicting defects and investigating casting methods by many casting companies. The mould filling is simulated to determine the actual filling time (to check the gating design for the ideal filling time), and identify the location and velocity of metal impingement on mould (to determine the possibility of mould erosion/sand inclusions). A layer-by-layer filling algorithm that considers the instantaneous velocity of metal through the ingate and the area of casting cross-section being filled up, is adequate to estimate the mould filling time.

This paper describes the advantages of the simulations to attain better casting system design in HPDC castings. Filling analysis is used to determine the size and location of the gate as well as proper runner system design for ensuring a complete and balanced filling of the part. Shot sleeve simulations in High Pressure Die Casting process ensures the minimum air entrapment during the pre-filling phase. The purpose of Simulation is to save time and reduce the cost of the casting system in design. At the same time it is possible to meet stringent product quality. Simulation can make a casting system optimal: it enables the producing of sound, high-quality castings with fewer experiments. Furthermore environmental savings and economical use of materials can be achieved when the number of test castings is reduced. Application of Simulation in Die casting can analyze the following Aspects:

Cavity fill, including full coupling with heat transfer, back pressure from the cavity gas, venting, and vacuum. Heat transfer and solidification, including solidification times, die temperatures, and casting temperatures. Casting distortion, including thermal shrinkage following ejection from the die and associated residual stress. More on solving die casting defects.

Contact details: Vijay S Mobile No: 9945369311 M.Tech , Tool Engineering GT&TC, Mysore.