Abstract
For the development of the manufacturing process of alternator housing, finite element simulation is applied. In recent years, automobile parts are required to be light and have high strength. The control of casting defects is important in die casting process. However, it has usually been depended on the experience of the foundry engineer. The die casting process was used to manufacture automotive alternator housings. In this paper, the die characteristics of alternator housing with the HPDC(High Pressure Die Casting) process were investigated using computer simulations. Through the simulations using the commercial software, the filling pattern and product defects could be confirmed. The computer simulation results of filling behavior were reflected to the optimal design of the alternator housing. The analysis results obtained from the filling behavior of casting process agreed with experimental results.
Highlights
The requirement of light weight and high performance automobiles has been increased
In this study, the filling and solidification process were predicted using computer simulation and its results were reflected in the die design and the process design as a previous step for the development of the precision die of an automotive housing
The existing casting technique is problematic for the production of the alternator housing products in that it cannot guarantee accuracy within the maximum circularity 0.1 based on an inner diameter 100
Summary
The requirement of light weight and high performance automobiles has been increased. The weight of the automobile is very important from the viewpoint of fuel consumption and traveling performance. Lightweight materials such as aluminum, magnesium, and titanium comes to be more important. Material techniques, process design for parts and die design techniques need to be developed for light weight automobile parts. The die casting is considered as an appropriate forming process to manufacture the products in which complex shapes or precision surfaces are desired. In this study, the filling and solidification process were predicted using computer simulation and its results were reflected in the die design and the process design as a previous step for the development of the precision die of an automotive housing
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