Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels

This article introduces the paper "Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels".

1. Overview:

• Title: Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels
• Authors: Pei-Hsing Huang, Wei-Jen Wu, Chung-Han Shieh
• Publication Year: April 2017
• Journal/Conference: Applied Mechanics and Materials
• Keywords:
  • low pressure die-casting
  • A356 aluminum
  • Anycasting
  • shrinkage defect
  • mold flow analyses

2. Research Background:

• Social/Academic Context of the Research Topic:
  • The automotive industry is vigorously developing lightweight, high-strength, and impact-resistant vehicle designs.
  • Low pressure die-casting is widely used for wheel production.
  • Defects during die-casting can lead to wheel frame deformation and creep damage, affecting traffic safety.
  • Ensuring high-quality die-casting wheel frame products is crucial.
• Limitations of Existing Research:
  • Existing research implicitly acknowledges the challenge of defects in low pressure die-casting of aluminum wheels due to complex shapes and high-speed filling.
  • Previous studies have used numerical simulation to predict defects and optimize parameters, but further improvement is needed to effectively eliminate defects.
• Necessity of Research:
  • To understand the evolution of mold flow, temperature field, and solidification in low pressure die-casting of A356 aluminum wheels.
  • To reduce defects occurring in wheel products through optimized casting parameters and designs of flow channels and overflows.
  • To predict defect positions and distributions to eliminate shrinkage voids and porosity defects.

3. Research Objectives and Research Questions:

• Research Objective:
  • To design and simulate the low pressure die-casting process of A356 aluminum wheels using Anycasting software.
  • To predict the formation of defects and improve defect reduction strategies by optimizing process parameters and overflow tank configuration.
• Core Research Question:
  • How can compute-aided design and simulation of the low pressure die-casting process, particularly through the use of Anycasting software and overflow tank optimization, effectively reduce shrinkage and porosity defects in A356 aluminum wheels?
• Research Hypothesis:
  • Setting up an overflow tank can effectively prevent the formation of shrinkage void and porosity of die-castings and significantly promote the quality and productivity of die-casting wheel products.

4. Research Methodology:

• Research Design:
  • Simulation-based study using numerical simulation technique.
• Data Collection Method:
  • Simulation data generated by Anycasting software package.
• Analysis Method:
  • Anycasting numerical simulation analysis, employing the finite difference method (FDM).
  • Retained melt modulus (RMM) analysis to predict defect positions and distribution.
  • Simulation of mold flow, temperature field, and solidification processes.
  • Analysis of process parameters and configuration design of overflow tank.
• Research Subject and Scope:
  • Low pressure die-casting process of A356 aluminum wheels.
  • Simulation analysis focused on lift wheel, wheel, and overflow tank with different overflow tank configurations.
  • Material: SKD61 die steel for mold and A356 aluminum for wheel casting.

5. Key Research Findings:

• Core Research Findings:
  • Setting up an overflow tank effectively prevents the formation of shrinkage void and porosity in A356 aluminum die-castings.
  • The use of an overflow tank significantly promotes the quality and productivity of die-casting wheel products.
  • Numerical simulation using Anycasting software can effectively predict the formation and distribution of defects in low pressure die-casting.
• Statistical/Qualitative Analysis Results:
  • Retained melt modulus (RMM) analysis was used to predict defect probability distribution.
  • Simulation results showed that defects were mainly distributed in the bottom of the rim and the wheel center in the initial approach without an overflow tank.
  • With the addition of an overflow tank, the independent residual melt, which contributes to defects, could be effectively discharged.
• Data Interpretation:
  • The initial approach with a taper opening lift tube (70° taper angle, 706.5mm² water entry sectional area) resulted in defects concentrated at the bottom rim and wheel center due to independent residual melt.
  • Adding an overflow tank facilitated the discharge of independent residual melt, redirecting shrinkage and porosity to the overflow tank and away from the wheel body.
• Figure Name List:
  • Fig. 1: (a) 3D Model of assembly of wheel and lift tube (b) results after mesh generation of physical model.
  • Fig. 2: Diagram of Low Pressure Die-casting Mold Filling.
  • Fig. 3: (a) external view & (b) cutaway view of defects probability distribution through retained melt modulus analysis of the initial approach of taper opening lift tube.
  • Fig. 4: Solidification Order Diagram of (a) Initial Approach (b) Improvement Approach by Adding of Overflow Tank.
  • Fig. 5: (a) External View, (b) Front View & (c) Rear View of Defects Probability Distribution via Retained Melt Modulus analysis of the Improvement Approach by Adding of Overflow Tank.

6. Conclusion and Discussion:

• Summary of Main Results:
  • The study demonstrated that adding an overflow tank in the low pressure die-casting process of A356 aluminum wheels effectively reduces shrinkage and porosity defects.
  • Numerical simulation using Anycasting software and RMM analysis accurately predicted defect formation and distribution.
  • The overflow tank design allowed for the venting of gas and the migration of shrinkage and porosity to the overflow tank, eliminating defects in the wheel rim and center.
• Academic Significance:
  • The research validates the use of compute-aided design and numerical simulation, specifically Anycasting software and RMM analysis, for optimizing low pressure die-casting processes.
  • It provides a detailed understanding of defect formation mechanisms related to independent residual melt and the effectiveness of overflow tanks in mitigating these defects.
  • The study contributes to the body of knowledge on die-casting process optimization for lightweight automotive components.
• Practical Implications:
  • The findings offer practical guidance for die-casting engineers to improve the quality and productivity of aluminum wheel manufacturing.
  • Implementing overflow tank designs, informed by simulation analysis, can lead to a significant reduction in defects, scrap rates, and manufacturing costs.
  • The study highlights the importance of considering mold flow, temperature field, and solidification during the design phase of die-casting processes.
• Limitations of Research:
  • The paper does not explicitly discuss the limitations of the research.

7. Future Follow-up Research:

• Future Research Directions:
  • Further research could explore the optimization of overflow tank designs in terms of size, shape, and placement for various wheel geometries and casting parameters.
  • Investigating the influence of different process parameters (e.g., casting temperature, pressure profiles, cooling rates) in conjunction with overflow tank designs could be beneficial.
  • Experimental validation of the simulation results through physical die-casting trials would further strengthen the findings.
• Areas for Further Exploration:
  • Exploring the application of this methodology to other aluminum alloys and die-casting processes.
  • Investigating the use of advanced simulation techniques and material models for even more accurate defect prediction.
  • Studying the impact of overflow tank design on the mechanical properties and fatigue life of the die-cast aluminum wheels.

8. References:

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[2] P. H. Huang, B. T. Wang, Y. T. Chen, An effective method for separating casting components from the runner system using vibration-induced fatigue damage, Int. J. Adv. Manuf. Technol. 74(9) (2014) 1275-1282 doi:10.1007/s00170-014-6077-z
[3] J. L. Chen, Automotive aluminum wheels low pressure casting process overview, Theor. Urban Construct. 13 (2014).
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[6] P. H. Huang, C. J. Lin, Computer-aided modeling and experimental verification of optimal gating system design for investment casting of precision rotor, Int. J. Adv. Manuf. Technol. 79(5) (2015) 997-1006.
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[8] G. F. Mi, X. Y. Liu, K. F. Wang, J. T. Niu, Numerical simulation of low pressure die-casting aluminum wheel, China Foundry, 48(1) (2009) 48-52.
[9] X. F. Huang, Z. Y. Tian, K. Zhu, X. J. Cao, R. Xie, Study and Application of Die-Casting Aluminum Alloy and Die-Casting Technology, Cast. Forg. Weld. 37(17) (2008) doi:1001-3814(2008)17-0137-05
[10] Y. J. Zhang, Study of Performance of Automobile Wheel of A356 AL-alloy by Low Pressure Casting, Foundry Technol. 35(2) (2014).

9. Copyright:

Copyright: This summary is based on the paper: Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels.

doi:10.4028/www.scientific.net/AMM.864.173

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