Modelling Die Filling in Ultra-Thin Aluminium Castings

Abstract:

Article Preview

This work aims to develop flow and thermal control methods for the high pressure die casting (HPDC) of very thin-walled aluminium components where thicknesses are predominantly less than 1 mm. One specific aim includes developing advanced modelling capability using CFD software to predict the complex structure of the metal flow in the die and the casting solidification. The modelling based on FLOW-3D started initially with a fluidity die study to establish several key parameters in HPDC modelling through experimental validation. A new test casting geometry has been designed in the form of a shallow tray with other features such as changes in curvature, fins and bosses. The casting thickness can be made variable in the die. The experimental work was conducted on a 250-tonne HPDC machine. Initial models of molten metal flow in the die cavity based on a runner design for casting thicknesses between 1.5 mm and 1 mm are presented. The detailed model required a very large mesh of very small elements, and more accurate physical parameters which may not have been previously available.

Info:

Periodical:

Edited by:

Hajo Dieringa, Norbert Hort and Karl Ulrich Kainer

Pages:

107-111

DOI:

10.4028/www.scientific.net/MSF.690.107

Citation:

T. Nguyen et al., "Modelling Die Filling in Ultra-Thin Aluminium Castings", Materials Science Forum, Vol. 690, pp. 107-111, 2011

Online since:

June 2011

Export:

Price:

$38.00

[1] Yamaha News Release, 5 Feb 2002: http: /www. snowmobilemod. com/CF_Aluminum. pdf.

[2] Michael Maj and Thomas N. Meyer: Ultra-Large Castings of Aluminum and Magnesium (AMD 406), USAMP 2007 Progress Report.

[3] Z. Brown, B. Szymanowki, M. Musser, D. Saha, S. Seaver and M. Hartlieb: Manufacturing of Thin Wall Structural Automotive Components through High Vacuum Die Casting Technology, NADCA Paper, 111th Metalcasting Congress, May 15-18, (2007).

[4] C. Kang, J. Cho, Y. Kim, C. Jeong and J. Park: Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing, NADCA Paper, 111th Metalcasting Congress, May 15-18, (2007).

[5] FLOW-3D User's Manual ver. 9. 4 (2009): http: /www. flow3d. com.

[6] Thang Nguyen, Maya Gershenzon and Vu Nguyen: A Study on Die Casting and Modelling in a Fluidity Die, CAST report 2010-504, 18 March (2010).

[7] A. Hamasaiid, G. Dour, M.S. Dargusch, T. Loulou, C. Davidson and G. Savage: Heat transfer coefficient and in-cavity pressure at the casting-die interface during high pressure die casting of magnesium alloy AZ91D, Met. Trans. A, 10A (2008).

DOI: 10.1007/s11661-007-9452-7

[8] L. Wang, M. Gershenzon, V. Nguyen and G. Savage: An Innovative Device for Vacuum and Air Venting, CastExpo'05, St Louis, Missouri, April 16-19, 2005, paper T05-073.

In order to see related information, you need to Login.