Lattice Structure for Improving Cooling Uniformity in HPDC Mould Corners

Title and Summary

Research Objective:
The study aims to improve the cooling uniformity in high-pressure die casting (HPDC) mold corners by designing and evaluating lattice structures.
Key Methodology:
A lattice structure was inserted into mold corners to optimize flow characteristics within cooling channels and enhance heat transfer performance.
Key Results:
The application of lattice structures significantly improved the cooling uniformity of mold corners, contributing to better casting quality and process efficiency.

Research Team Information

Authors:
Essam Abo-Serie^* and Samuel K. Koranteng-Agyarko
School of Engineering, University of Leicester, Leicester LE1 7RH, UK^*
Author to whom correspondence should be addressed.

Research Background and Objectives (Based on the Introduction Section)

Industrial Background:
HPDC processes are widely used in the automotive and electronics industries for producing lightweight metal components, where cooling uniformity in molds significantly impacts quality and production costs.
Specific Technical Challenges:
Heat accumulation in mold corners leads to uneven cooling, which adversely affects the mechanical properties and dimensional stability of cast components.
Research Goal:
To improve the cooling uniformity of mold corners and thereby enhance the quality and efficiency of HPDC components.

Main Objectives and Research Content

Problem:
Addressing heat accumulation and cooling non-uniformity in mold corners, which compromise product quality.
Stepwise Approach to Problem-Solving:
1. Analyze heat transfer issues in mold corners.
2. Design lattice structures and evaluate their thermal performance.
3. Validate the performance of lattice structures through simulations and experiments.
Key Figures:
- Figure 1:
  Caption: Lattice structure design applied to HPDC mold corners
  Alt text: 3D CAD model of a mold corner with a lattice structure, showing the placement of cooling channels and lattice patterns.
- Figure 2:
  Caption: Flow analysis results with and without lattice structures in cooling channels
  Alt text: Simulation results comparing flow velocity and temperature distribution before and after applying lattice structures.
- Figure 3:
  Caption: Experimental results evaluating the heat transfer performance of lattice structures
  Alt text: Graphs and bar charts showing heat distribution and reduction in heat accumulation in mold corners with lattice structures.

Results and Achievements

Quantitative Results:
Cooling uniformity in molds with lattice structures improved by over 20%, and heat accumulation in mold corners was reduced by 15% compared to conventional designs.
Qualitative Results:
Improved cooling uniformity enhanced the microstructural consistency and dimensional stability of the cast products, reducing defect rates.
Technical Achievements:
Lattice structure technology offers a novel approach to HPDC mold design, demonstrating potential for industrial applications.

Copyright and References

This summary is based on the paper "Lattice Structure for Improving Cooling Uniformity in HPDC Mould Corners" by Essam Abo-Serie^* and Samuel K. Koranteng-Agyarko.
Paper source: MDPI, Applied Sciences