Improving die casting processes through optimization of lubrication

Abstract

Lubrication plays a significant role among the processes that affect aesthetic quality in die casting. Nevertheless, comprehensive investigations are still missing in literature. In this paper, the effect of lubrication is investigated and optimized, by focusing on its influence on the die temperature. Indeed, since the surface quality of castings is related to the interaction between melt and die, lubrication allows ejection of castings without generating defects and cooling of the die, by preserving its surface. Hence, the die temperature should be accurately selected and spraying should be improved to achieve the optimal temperature. In the experimentation proposed, the lubricant release agent percentage and the lubrication duration have been varied to trade-off between some conflicting effects, while making the die temperature approach the ‘Nukiyama point’. At the same time, reduction of the cycle time has been obtained. The results corroborate the approach, since defects are reduced after optimization.