Abstract
The availability of tools for predicting quality in high pressure die casting is a challenging issue since a large amount of defects is detected in components with a consequent worsening of the mechanical behavior. In this paper, a tool for predicting the effect of the plunger motion on the properties of high pressure die cast aluminum alloys is explained and applied, by demonstrating its effectiveness. A comparison between two experiments executed through different cold chamber machines and the same geometry of the die and slightly different chemical compositions of the alloy is described. The effectiveness of the model is proved by showing the agreement between the prediction bounds and the measured data. The prediction model proposed is a general methodology independent of the machine and accounts for the effects of geometry and alloy through its coefficients.
Highlights
High pressure die casting (HPDC) is widely used for manufacturing components with high integrity and productivity
The quality and the mechanical properties of the parts depend on the features of the whole process [2], including the die, the temperature, the chemical composition of the injected alloy, the pressure exerted by the injection machine and the motion profile of the plunger
A reliable prediction model that accounts for the influence of the process on the static mechanical behavior and the internal quality of castings is still missing in the literature, except for the concepts and the methodology proposed in the previous work of the authors [6,12,13]
Summary
High pressure die casting (HPDC) is widely used for manufacturing components with high integrity and productivity. A reliable prediction model that accounts for the influence of the process on the static mechanical behavior and the internal quality of castings is still missing in the literature, except for the concepts and the methodology proposed in the previous work of the authors [6,12,13]. Such works propose a scalar parameter that summarizes the time-history of the plunger motion, through its acceleration, and allows for the comparison of different motion profiles having different shapes (i.e., different mathematical primitives), different maximum speed or first-stage speed. The comparison of the actual mechanical properties and the ones predicted by the model corroborates the correctness of the approach and the possibility to optimize HPDC through the proposed behavioral model
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