ProCAST General Presentation
Trang 1Case Study 3
Al HPDC
Trang 2Copyright © ESI Group, 2007 All rights reserved.
Case Study - Aluminum Die
Casting
Production problem solved with casting simulation
Improper mould filling in a multi-cavity steel die
Trang 3Aluminum Die Casting
Metal arrives at gate in the following sequence:
Cavity A, Cavity B & then Cavity C
A
B
C
Trang 4Copyright © ESI Group, 2007 All rights reserved.
Aluminum Die Casting
Metal arrives at gate in the following sequence:
Cavity A, Cavity B & then Cavity C
A
B
C
Trang 5Aluminum Die Casting
Short Shot shows flow imbalance between 3 cavities
A
B
C
Trang 6Copyright © ESI Group, 2007 All rights reserved.
Aluminum Die Casting
Turbulence in front of gate causes porosity
Vents & Overflows opposite gate bleed out the gas porosity
Added vent & overflow
Trang 7Aluminum Die Casting
Filling sequence shows last region to fill is at
180 degrees from gate Overflow ingates at this point were increased in size to bleed more gas porosity
Trang 8Copyright © ESI Group, 2007 All rights reserved.
Aluminum Die Casting
Tangential gate fills along one direction (1 stream of fluid) which better allows
us to place overflows to reduce porosity
Significant reduction in porosity (from 15%to less than 1%) (actual final gating design not shown for confidentiality)
Trang 9Aluminum Die Casting
Skin View of Fraction Solid
Hot spot near overflows
Reduced overflow ingate thickness and eliminated overflow near gate
Trang 10Copyright © ESI Group, 2007 All rights reserved.
Aluminum Die Casting
X-ray View of Fraction Solid
Hot spot near overflows Reduced overflow ingate thickness and eliminated overflow near gate