Abstract
High-pressure die casting dies are produced in most cases by conventional subtractive manufacturing processes. In this case, a massive design of the die usually ensures high stability during the casting process. However, at the same time, it leads to low flexibility in casting production and high material costs. The basic approach in the present work is to reduce the conventional subtractive production process of a die casting die in favor of a flexible, modular design, where only a few contour elements of the die have to be replaced for achieving different castings. In order to pave the way for this design principle, basic thermal and structural properties of a lightweight design die casting die were analyzed. The finite element calculations carried out showed that the modular lightweight die casting die consumes considerably less energy for preheating and during operation. Due to the reduced stiffness and material, however, calculated deformations and stresses in the die are considerably higher during the casting process. Although the initial calculation results look very promising, further knowledge must be gained in order to ensure the future success of modular lightweight die casting dies.
Highlights
The high-pressure die casting (HPDC) process is a highly automated industrial casting process and is used in particular for the production of geometrically complex components
The die casting die as well as the fixed and moving platen are symmetrical with respect to the x-axis, symmetry boundary conditions were enabled for both models in order to save computing times
Within the scope of this article, a die concept was presented which aims at a strong modularization of a highpressure die casting die
Summary
The high-pressure die casting (HPDC) process is a highly automated industrial casting process and is used in particular for the production of geometrically complex components. Almost 70% of German production is, currently accounted for by the automotive industry.[1] In the field of die casting, a die casting die is usually redesigned and manufactured for each individual component. The advances in the design process in companies have evolved in an evolutionary way These improvements are primarily the result of the designers’ experience, which results from the proven performance of die casting dies in operation as well as from the application of numerical calculation and optimization methods. The aim should, be to simplify the time-consuming and cost-intensive design and manufacturing process of die casting dies and to enable rapid implementation of product variants. This article, presents a concept for a modular lightweight die casting die in order to make the time-consuming and cost-intensive design and manufacture of the dies more efficient
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