Prediction and validation of shape distortions in the simulation of high pressure die casting
The use of the thermomechanical simulation is very infrequent in the metal casting industry although the associated results are really useful for the manufacturing process. The main reasons are the complexity, the long calculation times and the difficulties to interpret the results. The parts manufa...
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| Published in: | Journal of manufacturing processes Vol. 33; pp. 228 - 237 |
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| Main Authors: | , , , , , |
| Format: | Journal Article |
| Language: | English |
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01-06-2018
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| Abstract | The use of the thermomechanical simulation is very infrequent in the metal casting industry although the associated results are really useful for the manufacturing process. The main reasons are the complexity, the long calculation times and the difficulties to interpret the results.
The parts manufactured by metal casting processes cool from its filling temperature to ambient, which causes a certain stress-strain state. Although the stress levels might be significant, the main worry of the foundrymen is usually the shape distortion. That is, the mismatches between the desired dimensions and the real ones. The problem is that the results obtained from numerical simulation are not directly useful to cover this industrial necessity.
This work presents the prediction obtained using the thermomechanical simulation for the final dimensions of a component manufactured in aluminium alloy by high pressure die casting (HPDC) and its validation with the final dimensions of the manufactured component. The methodology established to forecast the mismatches with the reference geometry is also detailed, as it may be useful to encourage the use of this type of simulation in the metal casting industry. |
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| AbstractList | The use of the thermomechanical simulation is very infrequent in the metal casting industry although the associated results are really useful for the manufacturing process. The main reasons are the complexity, the long calculation times and the difficulties to interpret the results.
The parts manufactured by metal casting processes cool from its filling temperature to ambient, which causes a certain stress-strain state. Although the stress levels might be significant, the main worry of the foundrymen is usually the shape distortion. That is, the mismatches between the desired dimensions and the real ones. The problem is that the results obtained from numerical simulation are not directly useful to cover this industrial necessity.
This work presents the prediction obtained using the thermomechanical simulation for the final dimensions of a component manufactured in aluminium alloy by high pressure die casting (HPDC) and its validation with the final dimensions of the manufactured component. The methodology established to forecast the mismatches with the reference geometry is also detailed, as it may be useful to encourage the use of this type of simulation in the metal casting industry. |
| Author | Vicario, Iban Arratibel, Ernesto Mugarza, Aitz Idoiaga, Jon Kepa Anglada, Eva Meléndez, Antton |
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| Cites_doi | 10.1088/1757-899X/33/1/012055 10.1016/j.proeng.2015.12.584 10.1016/j.jmatprotec.2011.07.012 10.1016/j.proeng.2013.08.272 10.1016/S1006-7191(08)60119-2 10.4028/www.scientific.net/MSF.797.105 10.1007/s11661-999-0334-z 10.1016/j.applthermaleng.2011.07.052 10.1016/j.proeng.2015.12.585 |
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| Keywords | Thermal stress Finite elements Numerical simulation Shape distortion HPDC Aluminum alloy |
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| References_xml | – year: 1998 ident: bib0075 article-title: Theory of thermal stresses contributor: fullname: Weiner – volume: 33 start-page: 12055 year: 2012 ident: bib0020 article-title: Simulation of distortion and residual stress in high pressure die casting – modelling and experiments publication-title: MCWASP XIII IOP Conf Ser Mater Sci Eng contributor: fullname: Schumacher – volume: 211 start-page: 2123 year: 2011 end-page: 2131 ident: bib0035 article-title: Determination of interfacial heat-transfer coefficient during investment-casting process of single-crystal blades publication-title: J Mater Process Technol contributor: fullname: Zhang – volume: 30 start-page: 449 year: 1999 end-page: 455 ident: bib0025 article-title: A new hot-tearing criterion publication-title: Metall Mater Trans A contributor: fullname: Gremaud – volume: 31 start-page: 3996 year: 2011 end-page: 4006 ident: bib0055 article-title: Determination of the heat transfer coefficient at the metal-die interface for high pressure die cast AlSi9Cu3Fe publication-title: Appl Therm Eng contributor: fullname: Watson – volume: 63 start-page: 75 year: 2013 end-page: 83 ident: bib0050 article-title: Adjustment of numerical simulation model to the investment casting process publication-title: Procedia Eng contributor: fullname: Dominguez – start-page: 581 year: 1996 end-page: 617 ident: bib0080 article-title: Use of constitutive relations publication-title: Finite elem. 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year: 1998 ident: 10.1016/j.jmapro.2018.05.019_bib0075 contributor: fullname: Boley – year: 2014 ident: 10.1016/j.jmapro.2018.05.019_bib0040 contributor: fullname: Meléndez – ident: 10.1016/j.jmapro.2018.05.019_bib0085 |
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| SubjectTerms | Aluminum alloy Finite elements HPDC Numerical simulation Shape distortion Thermal stress |
| Title | Prediction and validation of shape distortions in the simulation of high pressure die casting |
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