Figure 1.1: Schematic showing the principal components of a hot chamber die casting machine [6]
Figure 1.2: Schematic showing the principal components of a cold chamber die casting machine [6]
Figure 2.1: The loads acting in different stages of a die casting operation [16]
Figure 2.2: Dimensional changes in the various steps of the die casting process [18]
Figure 2.3: Die distortion process in a die casting cycle
Figure 2.4: Schematic of the machine model used by Choudhary, et al [26]
Figure 3.1: Machine model used for simulation
Figure 3.2: Cover die with pillars that have been added in the new model
Figure 3.3: Contour plot for maximum principal stresses in the cover insert for the "cold die" case
Figure 3.4: Contour plot for maximum principal stresses in the cover insert for the "hot die" case
Figure 3.5: Contour plot for maximum principal stresses in the ejector insert for the "cold die" case
Figure 3.6: Contour plot for maximum principal stresses in the ejector insert for the "hot die" case
Figure 3.7: Contour plot for maximum principal stresses in the cover die for the "cold die" case
Figure 3.8: Contour plot for maximum principal stresses in the cover die for the "hot die" case
Figure 3.9: Contour plot for maximum principal stresses in the ejector die for the "cold die" case
Figure 3.10: Contour plot for maximum principal stresses in the ejector die for the "hot die" case
Figure 3.11: Contour plot for the displacement pattern in the inserts for the "hot die" case
Figure 3.12: A schematic showing the location of pillars and cooling lines on (a) cover die and (b) ejector die
Figure 3.13: Contour plot for the cover die displacement pattern for the "hot die" case
Figure 3.14: Contour plot for the ejector die displacement pattern for the "hot die" case
Figure 3.15: Contour plot for parting plane separation for "hot die" case with (a) clamp only and (b) clamp plus intensification
Figure 3.16: Contour plot for contact pressure for "cold die" case with (a) clamp only and (b) clamp plus intensification
Figure 3.17: Contour plot for contact pressure for "hot die" case with (a) clamp only and (b) clamp plus intensification
Figure 4.1: Schematic of die geometry
Figure 4.2: Layout of machine platen
Figure 4.3: Casting used for the study
Figure 4.4: Boundary conditions [10]
Figure 4.4: Parting plane separation pattern for case 1 (Note: Figure number duplication in source)
Figure 4.5: Parting plane separation pattern for case 2
Figure 4.6: Plot of Y and Yc for the design runs
Figure 4.7: Interaction between die size and die thickness
Figure 4.8: Interaction between die size and platen thickness
Figure 4.9: Interaction between die thickness and platen thickness
Figure 4.10: Interaction between die size and thickness ratio
Figure 4.11: Interaction between die thickness and thickness ratio
Figure 4.12: Interaction between platen thickness and thickness ratio
Figure 4.17: Interaction between die size and die thickness (Ycpred)
Figure 4.18: Interaction between die size and platen thickness (Ycpred)
Figure 4.19: Interaction between die size and thickness ratio (Ycpred)
Figure 4.20: Interaction between die thickness and platen thickness (Ycpred)
Figure 4.21: Interaction between die thickness and thickness ratio (Ycpred)
Figure 4.22: Interaction between platen thickness and thickness ratio (Ycpred)
Figure 4.23: Contour plot of dY/dA at C = -1
Figure 4.24: Contour plot of dY/dA at C = 0
Figure 4.25: Contour plot of dY/dA at C = 1
Figure 4.26: Contour plot of dY/dB
Figure 4.27: Contour plot of dY/dC
Figure 4.28: Contour plot of dYc/dA
Figure 4.29: Contour plot of dYc/dB
Figure 4.30: Contour plot of dYc/dC
Figure A.1: Parting plane separation plot for case 1
Figure A.2: Parting plane separation plot for case 2
Figure A.3: Parting plane separation plot for case 3
Figure A.4: Parting plane separation plot for case 4
Figure A.5: Parting plane separation plot for case 5
Figure A.6: Parting plane separation plot for case 6
Figure A.7: Parting plane separation plot for case 7
Figure A.8: Parting plane separation plot for case 8
Figure A.9: Parting plane separation plot for case 9
Figure A.10: Parting plane separation plot for case 10
Figure A.11: Parting plane separation plot for case 11
Figure A.12: Parting plane separation plot for case 12
Figure A.13: Parting plane separation plot for case 13
Figure A.14: Parting plane separation plot for case 14
Figure A.15: Parting plane separation plot for case 15
Figure A.16: Parting plane separation plot for case 16
Figure A.17: Parting plane separation plot for case 17
Figure A.18: Parting plane separation plot for case 18
Figure A.19: Parting plane separation plot for case 19
Figure A.20: Parting plane separation plot for case 20
Figure A.21: Parting plane separation plot for case 21
Figure A.22: Parting plane separation plot for case 22
Figure A.23: Parting plane separation plot for case 23
Figure A.24: Parting plane separation plot for case 24
Figure A.25: Parting plane separation plot for case 25
Figure A.26: Parting plane separation plot for case 26
Figure A.27: Parting plane separation plot for case 27
Figure A.28: Parting plane separation plot for case 28
Figure A.29: Parting plane separation plot for case 29
Figure A.30: Parting plane separation plot for case 30
Figure A.31: Parting plane separation plot for case 31
Figure 1.1: Schematic showing the principal components of a hot chamber die casting
machine [6] Figure 2.1: The loads acting in different stages of a die casting operation [16] Figure 2.3: Die distortion process in a die casting cycle
[7] NADCA, "NADCA Product Specification Standards for Die Casting", Third Edition, NADCA, 1997
[8] Ashish Vashist, "A study of industrial die casting die to predict parting plane separation and location of flash with different support setups". The Ohio State University, 2003
[9] Vashist, A., Kabiri-Bamoradian, K., Miller, R.A., "Die casting die distortion: Case study to predict parting plane separation and flash location", NADCA Transactions of the Congress & Table Exposition, Rosemont, Illinois, 2002
[10] Abhijith Chayapathi, "Study of the effect of structural die and machine variables on die deflections". The Ohio State University, 2000
[11] Chayapathi, A., Kesavan, V., Miller, R.A., "The effects of structural die and machine variables on die deflection". Transactions of the 20th NADCA Congress & Exposition, Cleveland, Ohio, 1999
[12] Abhay Tewari, "Study of the effect of structural variables of die and die casting machine on die deflections". The Ohio State University, 2000
[13] Miller, R.A., Chakravarthi, V., Kabiri-Bamoradian, K., Kulkami, Y., Tewari, A., "Modeling the Distortion and Mechanical Performances of Dies", NADCA Transactions, 2000
[14] Yogesh S Kulkami, "Study of the effect of structural variables of die and die casting machine on die deflections", The Ohio State University, 2001
[15] Miller, R.A., "Die deflection modeling: Empirical validation and tech transfer". Final report. Center for Die Casting, The Ohio State University, 2003
[16] Ahuett-Garza, H., Miller, R.A., "Die casting die deflections: Computer simulation of causes and effects", NADCA Transactions, 1997
[17] Kaye, A., Street, A., "Die Casting Metallurgy", Butterworth Scientific, 1982
[18] Barone, M.R., Caulk, D.A., "Analysis of Thermo-Mechanical Distortion in Die Casting", NADCA Transactions, 1999
[19] Ahuett-Garza, H., Hedge, K., Padiyar, G., Miller, R.A., "FEM analysis of die casting die deflections: Part I, Modeling and Simulation", NADCA Transactions, 1995
[20] Ahuett-Garza, H., Hedge, K., Padiyar, G., Miller, R.A, "FEM analysis of die casting die deflections: Part II, Results", NADCA Transactions, 1995
[21] Papai, J., Mobley, C; "Die thermal fields and heat fluxes during die casting of 380 aluminum alloy in H-13 steel dies"; NADCA Transactions, 1991
[23] IDEAS Version 10, Online Help Manual, Structural Dynamics Research Corporation
[24] ABAQUS Version 6.3, Online Documentation, Hibbitt, Karlsson and Sorrensen, Inc.
[25] Dedhia, S., Ahuett-Garza, H., Choudhury, A.K., and R.A. Miller, "Analysis of proud inserts in Die Deflections and Slide Blowback in Die Casting Dies", Transactions, 19th NADCA Congress & Exposition, Minneapolis, MN, 1997
[26] Choudhury, A.K., Dedhia, S., Ahuett-Garza, H., and R.A. Miller, "Study of the effects of platen size on die deflections". Transactions, 19th NADCA Congress & Exposition, Minneapolis, MN, 1997
[27] Venkat, G, R., Shah, V., Ahuett-Garza, H., Miller, R.A., "Parametric design applied to die casting", NADCA Transactions, 1995
![Figure 1.1: Schematic showing the principal components of a hot chamber die casting machine [6]](https://castman.co.kr/wp-content/uploads/image-144-png.webp)
![Figure 2.1: The loads acting in different stages of a die casting operation [16]](https://castman.co.kr/wp-content/uploads/Figure-2.1-The-loads-acting-in-different-stages-of-a-die-casting-operation-16-.webp)
