Casting Layout Design Using CAE Simulation : Automotive Part(Oil Pan_BR2E)

산업경영시스템학회지 = Journal of society of Korea industrial and systems engineeringv.40 no.1 , 2017년, pp.35 - 40  권홍규 (남서울대학교 산업경영공학과)

Abstract

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

Keywords

#Oil Pan   #Gate System   #Casting Layout   #CAE Simulation   #Melt Flow  

Image of Oil Pan
Image of Oil Pan
Casting Design of Oil Pan : (A) Case 1; (B) Case 2; (C) Case 3
Casting Design of Oil Pan : (A) Case 1; (B) Case 2; (C) Case 3
<Figure 5> Simulation Results for the Melt Flow of Case 1 : (A) 40% filling; (B) 80% filling
Simulation Results for the Melt Flow of Case 1 : (A) 40% filling; (B) 80% filling
<Figure 10> (A) 40% Filling Process on the Fixed Side of Case 3; (B) Final Casting Design
(A) 40% Filling Process on the Fixed Side of Case 3; (B) Final Casting Design

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