Design and optimization of gating system, modification of cooling system position and flow simulation for cold chamber high pressure die casting machine

Abstract

The failure of dies and its repairing options are very important in die casting industries. Of all the casting processes available, pressure die casting finds wide applications in large scale production of complex shaped objects with intricate geometries that require good surface finish and dimensional stability. The cooling system employed in the die not only facilitates proper solidification of the cast components but also helps in maintaining the die temperature and controlling the stresses generated during the cyclic operation. The research work focuses on designing a die of H13 material for ADC12 cast part that is to be operated on 160 Tonne Cold Chamber HPDC machine. The effect of cooling system location on the stresses produced in die is analysed and their optimum location is determined by ANSYS. Further, filling simulation of the modified design was carried out and minor modifications are made to optimize the filling operation using MAGMA Software. The research work proves to be useful in increasing the die life by considering the optimization of cooling channel position along with the gating system design in the design stage.