This introductory paper is the research content of the paper "Thermal Factor of Aluminium High pressure Die Casting Container (Mould) to achieve Six Sigma Quality of Castings" published by IJERT.
1. Overview:
- Title: Thermal Factor of Aluminium High pressure Die Casting Container (Mould) to achieve Six Sigma Quality of Castings
- Author: Suraj Marathe, Dr. Carmo Quadros
- Publication Year: 2020
- Published Journal/Society: International Journal of Engineering Research & Technology (IJERT)
- Keywords: High Pressure Die-casting (HPDC); Preheating temperature; Six Sigma quality of a casting; ProCast
2. Abstract
This paper deals with the analysis of the temperature factors of aluminium high pressure die casting Container (mould). It also describes the development of expression for preheating temperature factor of mould to maintain the molten aluminium temperature, which gives the six sigma quality product depending on the degree of preheating of mould. The monitored temperature factors are very much important in the die-casting process, which is positively reflected in production efficiency and the quality of the casting. In die casting, the melted metal is pressed under high temperature into a mould cavity of significantly lower temperature. The mould is then exposed to a thermal strain of individual surface layers of the mould material. The speed of cooling of the castings in the metal mould increases, causing an increase of thermal gradients in the casting. Intensive heat exchange between the castings And the metal mould harms fluidity, which increases the danger of incomplete replenishment and the occurrence of cold joints. Analysis and optimization were performed with the help of ProCast Simulation software which uses Finite Element Analysis Technology.
3. Research Background:
Background of the research topic:
Die casting is a high-volume manufacturing process for metal parts, particularly aluminum alloys. Aluminum alloys offer lightweight and high dimensional stability for complex shapes. However, casting defects are common, making the process inherently uncertain.
Status of previous research:
- The global market demands high-quality castings, driving the need for efficient techniques like Six Sigma [1].
- Casting quality is influenced by thermal and technological factors, including temperatures of the alloy, filling chamber, and mould [3, 6].
- Numerous factors affect pressure die castings, such as pressing velocity, pressure, and filling time [7].
- Prior work includes optimization of die casting [13, 14], gating system redesign [5], DOE and Taguchi methods [1, 11], flow simulation [15, 16], and thermal factor analysis [17].
- A stable finite difference scheme has been used for 3D thermal analysis in die casting [8].
- Semi-solid die casting has been studied for improving mechanical properties [9].
- Rejection levels in casting are typically 11-13%, motivating efforts to reach Six Sigma limits [1].
Need for research:
Despite existing research, many factors and problems in die casting remain unexplained. This study specifically addresses the impact of thermal factors on casting quality. The need is to reduce rejection and to achive six sigma quality.
4. Research purpose and research question:
Research purpose:
To investigate the effects of thermal factors in a die casting process on the quality of cast product and optimize the process using ProCast Simulation.
Core research:
- Identify critical parameters (thermal and pressure) contributing to casting rejection.
- Develop an expression for the preheating temperature factor of the mould.
- Analyze and optimize the preheating temperature using ProCast software.
5. Research methodology
- Research Design: Experimental and simulation-based.
- Data Collection:
- Critical parameters (molten metal, mould, and filling chamber temperatures; intensified and clamping pressures) were monitored.
- ProCast Simulation software, using Finite Element Analysis, was employed.
- Experimental setup: 100T HPDC machine, diesel-fired holding furnace, close-loop cooling system.
- Products: Die-casted rotors (100S, M50, B48) with varying dimensions.
- Analysis Method:
- A thermal balance equation (Equation 7) was developed to determine the required mould preheating temperature.
- ProCast simulation was used to validate the equation and analyze mould temperature evolution.
- Cause and effect diagram (Fig. 1) was used to identify process parameters.
6. Key research results:
Key research results and presented data analysis:
- A heat balance equation (Equation 7) was derived to calculate the required preheating temperature. This equation considers factors like:
- Weight and surface area of the casting.
- Specific heat of molten and solid aluminum.
- Temperatures of molten and solidus aluminum.
- Latent heat of solidus aluminum.
- Heat transfer coefficient.
- Casting temperature upon removal from the mould.
- The equation was validated using ProCast simulation.
- Preheating temperatures for 100S and M50 rotors were determined (63.68°C and 76.33°C, respectively) to achieve six sigma quality.
- Simulation showed mould temperature reaching a peak of 475°C, affecting filling time (Fig. 3 and Fig. 4).
- Mould temperature can be controlled by regulating the cooling system flow (Fig. 5 and Fig. 6).
- Filling time is less in case of preheating temperature.
List of figure names:
- Fig 1: Cause and Effect Diagram for Casting Defects
- Fig.2: Mesh Model of the 100S and M50 Frame Rotors.
- Fig.3: Mould Thermal evolution during pre-heating of M50 Rotor cycles simulation
- Fig 4: Mould thermal evolution during pre-heating of 100S Rotor cycle simulation
- Fig 5: Mould temperature for M50 rotor
- Fig 6: Mould Temperature for 100S Rotor
- Fig 7: Simulated results for 100S rotor for filling time
- Fig 8: Simulated results for M50 rotor for filling time
7. Conclusion:
Summary of key findings:
- The thermal balance equation accurately predicts the required preheating temperature for different casting sizes.
- Filling time is reduced with preheating.
- The preheating temperature, calculated by the thermal equation, should be maintained by controlling the cooling system's flow.
- Using the heat balance equation, waste shots due to improper preheating can be eliminated.
{Summary of research results. Academic significance of the research, practical implications of the research}
The thermal balance equation is beneficial to improve the thermal parameters, predicting the defects related to the filling process, as to achieve the six sigma products.
8. References:
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9. Copyright:
- This material is a paper by "Suraj Marathe, Dr. Carmo Quadros": Based on "Thermal Factor of Aluminium High pressure Die Casting Container (Mould) to achieve Six Sigma Quality of Castings".
- Source of paper: http://www.ijert.org
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