This introductory paper is the research content of the paper ["Design of Single Cavity Pressure Die Casting Die for Automotive Part of Aluminum Alloy (AlSi-12) Using CAD Tool & Its Manufacturing by HPDC Technology"] published by [Journal Publication of International Research for Engineering and Management (JOIREM)].
1. Overview:
- Title: Design of Single Cavity Pressure Die Casting Die for Automotive Part of Aluminum Alloy (AlSi-12) Using CAD Tool & Its Manufacturing by HPDC Technology
- Author: Rakesh Bandane, Vaibhav Bankar
- Publication Year: may-2022
- Publishing Journal/Academic Society: Journal Publication of International Research for Engineering and Management (JOIREM)
- Keywords: Single Cavity Pressure Die Casting Die, UNIGRAPHICS NX
2. Abstracts / Introduction
Abstract
"Manufacturers can create a sharply defined textured or smooth surface of metal parts by using a manufacturing process described in high-pressure die-casting technology. The mechanism under this technology forces and injects molten metal into a reusable metal die at a speed of 27-45 m/s. The manufacturers will use the hot chamber or cold chamber method to inject the metal into the die on the basis of the type of metal chosen to fabricate the part. The designer must incorporate numerous manufacturability-related factors into the design of a die to produce successful castings economically. To achieve this overall design goal, the die fills completely with molten metal, quickly & consistent solidification of molten metal, the part ejects easily from the die without damage, the part requires a minimum of die construction and die maintenance difficulties, the part meets the customer's tolerance requirement. Proper estimation of part manufacturing is essential for tender procurement & reduction in manufacturing lead time. The project gives a brief introduction of design considerations in manufacturing single cavity pressure die casting die. It explains the process flow from quotation to dispatch of the PDC tool. UNIGRAPHICS NX software is used for doing the work accomplished in design."
Introduction
This paper elucidates the design and manufacturing considerations for single cavity pressure die casting dies, emphasizing their application in producing automotive components from Aluminum Alloy (AlSi-12). Die casting, a process involving the injection of molten metal under pressure into metal molds, is highlighted for its capability to produce complex shapes at high velocities, contrasting with gravity-dependent permanent mold casting. The process involves die closure and locking, molten metal delivery via plunger or pump, and controlled injection speed to ensure complete die fill and air expulsion through vents. Pressure is maintained during solidification, followed by die opening and casting ejection. Cyclic die cleaning and lubrication are integral to the process. The design process, from quotation to dispatch of the Pressure Die Casting (PDC) tool, is facilitated by UNIGRAPHICS NX software.
3. Research Background:
Background of the Research Topic:
The research addresses the critical role of High Pressure Die Casting (HPDC) in mass production, particularly for components requiring intricate geometries. Traditional sand casting is deemed inefficient for high-volume production, necessitating processes like HPDC. Die design for HPDC is identified as a crucial and complex task, requiring expertise in CAD and CAE to optimize die layout and flow simulation for effective design configuration.
Status of Existing Research:
Existing manufacturing processes, including permanent mould casting, are contrasted with die casting, emphasizing die casting's advantage in producing complex shapes due to high-velocity metal flow induced by pressure. The paper implicitly acknowledges the established nature of die casting technology while focusing on optimizing the design process for specific applications.
Necessity of the Research:
The research is motivated by the need for efficient and economical production of die castings. It highlights the importance of considering manufacturability-related factors in die design to achieve successful castings. Proper design ensures complete die fill, rapid and consistent solidification, easy part ejection, minimal die construction and maintenance, and adherence to customer tolerance requirements. Accurate manufacturing estimation is crucial for cost-effective tender procurement and reduced manufacturing lead times.
4. Research Purpose and Research Questions:
Research Purpose:
The primary objectives of this research are:
- "To study the type and the nature of the process to determining the layout of the die."
- "To identify the parameter for die design"
- "To conduct flow analysis for the component for solidification and filling"
- "To identify areas of concern for the potential defects in the casting"
- "To decide upon the type and the location of the gate/ runner/ feeder system"
- "To design the die for effecting a good quality component (defect free)"
- "To perform trial and testing for experimentation to validate the design"
Key Research:
This research aims to address key questions related to single cavity pressure die casting die design, including:
- What are the critical parameters influencing die layout and design in HPDC?
- How can flow analysis be effectively utilized to optimize component solidification and filling within the die?
- What are the potential defect areas in die castings, and how can die design mitigate these?
- What are the optimal gate, runner, and feeder system configurations for single cavity dies?
- How can a defect-free, high-quality component be achieved through optimized die design?
- How can design validation through experimentation ensure the die's performance and casting quality?
5. Research Methodology
Research Design:
The research employs a design-based approach, focusing on the design and manufacturing process of a single cavity pressure die casting die. It integrates CAD modeling using UNIGRAPHICS NX software to design a die for an automotive component (Cover CJ 145 mm LEFT & RIGHT). The design process follows a structured approach, from understanding component specifications to process validation.
Data Collection Method:
Data collection is implicit in the design process, primarily involving component specifications ("Component name: Cover CJ 145 mm LEFT & RIGHT", "129500 & 129520."), material selection ("Material : Aluminum alloy"), and operational parameters ("Work order no: 1023005", "Customer name: Akar Industries Pvt. Ltd., Nagpur."). The research also uses established die casting design principles and guidelines as data sources.
Analysis Method:
The analysis methods include:
- Flow Analysis: "To conduct flow analysis for the component for solidification and filling" is listed as an objective, indicating computational fluid dynamics (CFD) or similar simulation techniques are likely employed, although not explicitly detailed in the provided text.
- Design Calculations: Calculations for gate design, runner design, clamping force, and die casting machine selection are performed based on established formulas and empirical data.
- Design Validation: "To perform trial and testing for experimentation to validate the design" suggests physical experimentation and testing of the designed die to validate its performance.
Research Subjects and Scope:
The research focuses on the design of a single cavity pressure die casting die for a specific automotive part, "Cover CJ 145 mm LEFT & RIGHT," made of Aluminum Alloy (AlSi-12). The scope encompasses the entire design process from conceptualization to manufacturing considerations and validation, utilizing UNIGRAPHICS NX software as the primary CAD tool. The study is limited to single cavity die design and does not explicitly explore multi-cavity dies or other die casting variations.
6. Main Research Results:
Key Research Results:
The paper details the design process and calculations for a single cavity pressure die casting die. Key results are presented in the "3. DESIGN CALCULATION" section, including:
- Mould Data: Material (Aluminum Alloy (AlSi- 12)), Shrinkage (0.6%), Ejection stroke (43mm), Mould size (620x580x392mm).
- Gate Calculation: Weight across gate (588gms), Minimum wall thickness (2.50mm), Fill time (0.06sec), Gate velocity (4000cm/sec), Gate area (0.98mm²), Gate length (302mm), Gate thickness (0.83mm), Overflow opening area (100%). Calculated Gate area is later revised to 41.85 mm² and Gate thickness to 1 mm.
- Die Casting Machine Selection: Machine type (400T).
- Runner Calculation: Runner area (125mm²), Runner thickness (8 mm).
- Material Planning: Bill of Materials detailing components, dimensions, materials, and quantities (Table 1).
- Process Flow (Flow Chart): A 7-stage process flow from "Design Input" to "Design Changes" (Figure not explicitly named but described as "Process Flow (Flow Chart)").
- Assembly Views: Illustrations of Fixed Half Assembly, Moving Half Assembly, Ejector Assembly, Feed System, and Exploded View of Assembly (Figures 7.1.3, 7.1.4, 7.1.5, 7.1.6, 7.1.7).
Analysis of presented data:
The design calculations section demonstrates a systematic approach to determining die parameters. The gate and runner calculations are based on fluid flow principles and empirical ratios. The machine selection is based on clamping force requirements derived from the projected area and injection pressure. The Bill of Materials provides a comprehensive list of components for die assembly, crucial for manufacturing and procurement. The Process Flow Chart outlines a structured design process, incorporating design review, verification, and validation stages. The assembly views visually represent the die design, aiding in understanding its construction and operation.
Figure Name List:
- Fig. 7.1.1 Fixed Insert
- Fig. 7.1.2 Moving Insert
- Fig. 7.1.3 Fixed Half Assembly
- Fig 7.1.4 Moving Half Assembly
- Fig. 7.1.5 Ejector Assembly
- Fig. 7.1.6 Feed System
- Fig. 7.1.7 Exploded View of Assembly
7. Conclusion:
Summary of Key Findings:
The study successfully designed a single cavity pressure die casting die for an automotive component using CAD tools and detailed the manufacturing considerations. Key findings include the calculated parameters for gate, runner, clamping force, and machine selection, along with a structured design process flow and a comprehensive Bill of Materials. The research highlights the application of UNIGRAPHICS NX in die design and provides a practical example of designing a die for an Aluminum Alloy (AlSi-12) automotive part.
Academic Significance of the Study:
This study contributes to the practical application of die casting design principles by providing a detailed case study of single cavity die design. It demonstrates the integration of CAD tools and engineering calculations in a real-world design scenario. The structured approach to die design and process planning presented in the paper can serve as a reference for engineering students and practicing die designers.
Practical Implications:
The research offers practical guidelines and a step-by-step approach for designing single cavity pressure die casting dies. The detailed calculations, process flow, and Bill of Materials provide valuable information for die manufacturing and production planning. The use of UNIGRAPHICS NX and the emphasis on design validation highlight industry-relevant practices for efficient and quality die casting production. The guidelines for design (section 2.2) and process planning (section 5) offer actionable insights for improving die design and manufacturing processes.
Limitations of the Study and Areas for Future Research:
The study is limited to the design of a single cavity die for a specific automotive component and material. It lacks explicit details on flow analysis methodology and experimental validation results. Future research could expand upon this work by:
- Including detailed flow analysis simulations and experimental validation data to verify design performance.
- Investigating multi-cavity die designs and comparing their performance with single cavity designs.
- Exploring the application of design optimization techniques to further enhance die performance and casting quality.
- Investigating different Aluminum alloys and other materials for die casting applications.
- Analyzing the economic aspects of the designed die, including production cost and efficiency.
8. References:
- [1] Bharat Sharma, Hidden Parameter in High Pressure Die Casting, International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 10 | Oct 2020.
- [2] A. Nouri-Borujerdi, J. A. Goldak, Modeling of Air Venting in Pressure Die Casting Process , Journal of Manufacturing Science and Engineering AUGUST 2004, Vol. 126 Copyright © 2004 by ASME.
- [3] Raimo Helenius a, *, Otto Lohne a, Lars Arnberg a, Hans I. Laukli b, The heat transfer during filling of a high-pressure die-casting shot sleeve, Received in revised form 21 July 2005, Materials Science and Engineering A 413-414 (2005) 52–55.
- [4] Paul Robbins, Plunger Design-A Key to the Successful Die Casting System, 11the Metal Casting Congress, May 15-18, 2007, Houston, Texas , NADCA, 241 Holbrook, Wheeling, Illinois, 60090.
- [5] Bing Zhou, Yonglin Kang *, Mingfan Qi, Huanhuan Zhang and Guoming Zhu, R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy, Materials 2014, 7, 3084-3105; doi:10.3390/ma7043084, Received: 24 March 2014; in revised form: 4 April 2014 / Accepted: 4 April 2014 / Published: 15 April 2014.
- [6] Acceptance Criteria's, Book, author IGTR, AURANGABAD.
- [7] Steel Solutions, Author, STEEL-DEAL.
- [8] Industrial Steels (Reference Book), Author, S.N.Bagachi, Kuldip Prakash.
9. Copyright:
- This material is "Rakesh Bandane, Vaibhav Bankar"'s paper: Based on "Design of Single Cavity Pressure Die Casting Die for Automotive Part of Aluminum Alloy (AlSi-12) Using CAD Tool & Its Manufacturing by HPDC Technology".
- Paper Source: [DOI URL]
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