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Abstract Various analytical FEM, FDM tools for flow process including die casting have presented, they are only giving information to predetermined die design whether it is proper or not. Current shop floor practice uses the trial-and-error methods to determine new die design. This paper describes a research work of developing computer-aided die design system for die casting. Approach to the CAD system has been written in circumstance Auto LISP with personal computer. This system has been developed to present algorithms for automation of die design, especially runner-gate system using 3-D geometry. This system quantifies practical knowledge and experiences in die design as formulating procedure. It is possible for engineers to make automatic and efficient design of and it will result in reduction of required expenses and time. It is composed of selection of cast alloy, product design, runner-gate design etc. In addition, specific rules and equations for the system have been presented. An example is applied to cap-shaped cast using the proposed system.
Key words : Die casting, Die design system, Rule base, Runner, Gate
NOMENCLATURE
Qa Vg tg K q' L Cp Tm Ts Td S X volume of cavity to be filled, cm3 main gate velocity, m/sec filling time, sec heat capacity per unit volume, cal the rate heat evolved per unit time during solidification, cal/sec latent heat during solidification, cal/g specific heat of molten metal, cal/g temperature of molten metal, solidus temperature, die temperature, density of alloy, g/cm3 radiation area, cm2 a half thickness of cast, cm
1. INTRODUCTION
Die casting is one of the most economical casting processes for manufacturing precision shaped parts in mass production. It is a precise casting method in which molten metal is injected at high pressure into a die cavity. As soon as the molten metal has filled the cavity, it solidifies by fast cooling. Die-cast components are being used increasingly in the automobile, aerospace, electronic and other industries because of their premium quality, low cost and low weight. Because of high pressure and short cycle times involved, thin-wall sections are possible. In die-design system of various forming processes, Shaffer developed progressive die design by computer (PDDC) system and J.P. Kruth made efforts to develop an integrated CAD/CAM system for mould design and manufacture. J.C. Choi developed a compact and practical CAD system for blanking or piercing of irregular shaped- sheet metal products and statorrotor parts. In studies of die casting process, C.C Thai used runner-optimization design method and the abductive network in modeling the die casting process according to the experimental data. W. Zhang researched the CAD/ CAE system that die designer can determine the shape and dimension of runner-gating system under different casting condition. Generally speaking, die designer still have to depend on engineers experiences and know-how due to lack of proper analytical ability metal flow and velocity and heat transfer in die. Current shop floor practice uses the trial-and-error method to determine die design, when new moulds are used. This method is costly and results in a lot of wasted casting. To solve this problem a study was done on the runner and gate system to simulate the molten metal flow and to analyze the pressure and metal movement during casting process. Although some finite element analysis software is capable of analyzing the melting process and flow conditions of the products (workpiece) under various injection conditions, they are only giving some limited suggestions and information to die design. In this study, die design system for die casting process has been developed to present flow chart for automation of die design, especially runner-gate system. In addition, specific rules and equations for runner-gate system have been presented to avoid too many trials and errors with expensive equipment. It is possible for engineers to make an automatic and efficient die design and it will result in reduction of expense and time.
An example of cast product is seen in Fig.1. It is generally composed of cast cavity, gate, runner, biscuit, overflow and to be formed out from die. Irrespective of the shape of the cast, the quality is always determined by the runner-gate system. Generally, the system contains their arrangements and shapes to design properly. The effects of metal velocity and die temperature on the metal flow distance and quality are discussed.
Guide pins Holding Block Overflow Cavity Block Cast Gate Runner Biscuit Shot Chamber
Surface pin
Ejector pins
Essential components of simple casting die are illustrated in Fig.2. A die consists of two sections at the die parting plane. It is split into two sections so that the casting can be removed after it has been formed. These two sections are called the cover die (moving die) half and ejector die (fixed die) half. The cover die half may be machined in the solid cover die half, or it may be inserted. The cover die half is fastened to the stationary platen on the casting machine and does not move during the casting cycle. The ejector half is mounted on the movable platen of the machine. A cavity block that is a reproduction of a section of the part that is to be a casting is formed or machined into two halves of the die block.
Cast design Die Layout Design Gate Design Runner Design RunnerGate system Overflow Design Die Generation
Cavity Block Design Die type -One side -Both side Die Generation
In this study, die design system means automated generation system that master mould and other components are generated automatically when three-dimensional drawing of product is prepared. If a drawing of product is input into an AutoCAD by output drawing file on a screen, product design will be carried out and the size of die block will be determined.
This system is roughly composed of cast (product to be formed) design, and die layout design and die generation. Fig.3 shows the flow chart of the system. The shapes of each component are determined by rule-base and are connected at specified position by assembly flow chart. After components and casting are connected, the shapes of two die halves and layout are determined. And die design is finished after user's confirmation. This might be analyzed by commercial CAE software if the design is proper or not.
Confirm?
No
Yes Gate
Ag =
Qa Vg tg
(1)
The filling time of die cavity, tg is assigned to be that a fraction of solidus comes up to 70 %. Heat capacity per unit volume, K is given by (2)
K = [ L + C p (T m T s )] S X
The flow rate heat per unit time, q' is given by (3)
(2)
q = S (T m T d ) / X K q
(3)
From the equation (2) and (3), filling time, tg can be obtained.
tg =
0 .7
(4)
Generally, the gate thickness, t is selected properly, which is between 0.5 and 3.0mm, considering trimming etc. The width of gate L is determined by following equation from gate area calculated by equation (1).
L=
Ag t
(5)
Depth(D)
Radius(R) Width(W)
parts: gate-cavity, gate-runner, cavity-overflow and overflow-airvent. The cavity is subtracted from die block, and then die is split into two dies, moving and fixed dies. Finally die is generated on the determined parting plane.
Parting surface
Gate
Overflow
Runner
Airvent
Confirm?
No
5. CONCLUSIONS
The primary conclusions of this study are as follows. 1. This study proposed an easy and effective die design system for die casting product . It is constructed with die design algorithm and database in the circumstance AutoCAD. A novice who may not have any experience of die design can perform die design, especially runner-gate design only if he has a little knowledge about die casting. 2. A novice who may not have any experience of die design can perform it only if he has a little knowledge about die casting. But this system cannot be applied for solidification, flow analysis, and NC machining data because it is constructed with simple wire frames. And the used lines for geometries of object are only straight. 3. This system is basic at present and was applied to the simple cap-shaped cast. Next, this system will be applied more complex shape with more developed system.
ACKNOWLEDGEMENTS
The authors wish to acknowledge Brain Korea 21 of Department of Mechanical Engineering, Dong-Eui University, Pusan, Korea.
REFERENCES
Schaffer, G. Computer Aided Design of Progressive Dies. American Machinist 1971, 22, 73-75. Kruth, J.P. Steps Toward an Integrated CAD/CAM System for Mould Design and Manufacture: Anisotropic Shrinkage, Component Library and Link to NC Machining and EDM. Annals of the CIRP 1986, 35-38. Abrahams, M. ; Doble, M. CAD/CAM Integration for Producing Injection Moulds. ZWF Z. Wirtsch. Fertigung 1985, 80 (9), 60-62. Choi, J.C. ; Kim, B.M. ; Cho, H.Y. ; Kim, C. A Compact and Practical CAD System for Blanking or Piercing of Irregularshaped Sheet Metal Products and Stator and Rotor Parts. Inter. J. of Machine Tool & Manufacture 1998, 931-963. Thai, C.C. ; Lim, J.C. A Runner-optimization Design Study of a Die-casting Die. Journal of Materials Processing Technology 1998, 84,1-12 Thai, C.C. ; Lim, J.C. The Optimal Position for the Injection Gate of a Die-casting Die. Journal of Materials Processing Technology 1999, 86, 87-100 Zhang, W. ; Xiong, S. ; Liu, B. Study on a CAD/CAM System of Die Casting. Journal of Materials Processing Technology 1997, 63, 707-711. Sulaiman, S. ; Keen, T.C. Flow Analysis along the Runner and Gating System of a Casting Process. Journal of Materials Processing Technology 1997, 63, 690-695.