Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

Simulation of mold filling and prediction of gas entrapment on practical high pressure die castings

Element parameters including volume filled ratio,surface dimensionless distance,and surface filled ratio for DFDM(direct finite difference method)were proposed to describe shape and location of free surfaces in casting mold filling processes.A mathematical model of the filling process was proposed specially considering the mass,momentum and heat transfer in the vicinity of free surfaces.Furthermore,a method for gas entrapment was established by tracking flow of entrapped gas.The model and method were applied to practical ADC1 high pressure die castings.The gas entrapment prediction was compared with the fraction and maximum size of porosities in the different casting parts.The comparison shows validity of the proposed model and method.The study indicates that final porosities in high pressure die castings are dependent on both gas entrapment during mold filling process and pressure transfer within solidification period.

Cross-sectional distortion behaviors of thin-walled rectangular tube in rotary-draw bending process

The cross-sectional distortion usually appears during rotary-draw bending process of thin-walled rectangular tube with small bending radius.To study the cross-sectional distortion of the tube,a three-dimensional finite-element model of the process was developed based on ABAQUS/Explicit code and its reliability was validated by experiment.Then,the cross-sectional distortion behaviors of the tube were investigated.The results show that a zone of larger circumferential stress appears on the tube when bending angle reaches 30°.And in the larger circumferential stress zone,the sagging phenomenon is produced obviously.The maximum cross-sectional distortion is located in the larger circumferential stress zone and the angle between the plane of maximum cross-sectional distortion and the bending reference plane is about 50°.The position of the maximum cross-sectional distortion keeps almost unchanged with the variation of the clearances between dies and tube.

Mold Wear During Die Forging Based on Variance Analysis and Prediction of Die Life

A process parameter optimization method for mold wear during die forging process is proposed and a mold life prediction method based on polynomial fitting is presented,by combining the variance analysis method in the orthogonal test with the finite element simulation test in the forging process.The process parameters with the greatest influence on the mold wear during the die forging process and the optimal solution of the process parameters to minimize the wear depth of the mold are derived.The hot die forging process is taken as an example,and a mold wear correction model for hot forging processes is derived based on the Archard wear model.Finite element simulation analysis of die wear process in hot die forging based on deform software is performed to study the relationship between the wear depth of the mold working surface and the die forging process parameters during hot forging process.The optimized process parameters suitable for hot forging are derived by orthogonal experimental design and analysis of variance.The average wear amount of the mold during the die forging process is derived by calculating the wear depth of a plurality of key nodes on the mold surface.Mold life for the entire production process is predicted based on average mold wear depth and polynomial fitting.

Theoretical modeling of cutting temperature in high-speed end milling process for die/mold machining

A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating under cutting and cooling under non-cutting. It shows that cutting speed and the tool-workpiece engagement condition are determinative for tool temperature in the operation. The suggested model was investigated by tests of AlTiN coated endmill machining hardened die steel JIS SKD61, where cutting temperature on the flank face of tool was measured with an optical fiber type radiation thermometer. Experimental results show that the tendency of cutting temperature to increase with cutting speed and engagement angle is intensified with the progressing tool wear.

Low-cycle fatigue behavior of permanent mold cast and die-cast Al-Si-Cu-Mg alloys

Fatigue failure is one of the main failure forms of Al-Si-Cu-Mg aluminum alloys. To feature their mechanical aspect of fatigue behavior, the low-cycle fatigue behavior of permanent mold cast and die-cast AI-Si- Cu-Mg alloys at room temperature was investigated. The experimental results show that both permanent mold cast and die-cast AI-Si-Cu-Mg alloys mainly exhibit cyclic strain hardening. At the same total strain amplitude, the diecast AI-Si-Cu-Mg alloy shows higher cyclic deformation resistance and longer fatigue life than does the permanent mold cast AI-Si-Cu-Mg alloy. The relationship between both elastic and plastic strain amplitudes with reversals to failure shows a monotonic linear behavior, and can be described by the Basquin and Coffin-Manson equations, respectively.

Mold Filling and Prevention of Gas Entrapment in High-pressure Die-casting

This paper presents some results of direct observation of mold filling in a specially designed die-casting by X-ray diffraction, including comparison with numerical simulation. Based on such work the authors discuss how to prevent gas entrapment and propose new methods.

Microstructure and properties of nano-TiN modified Ti(C,N)-based cermets fabricated by powder injection molding and die pressing

Powder injection molding （PIM） and die pressing were employed to fabricate nano-TiN modified Ti（C,N）- based cermets. The shrinkage behavior, microstructure, porosity, and mechanical properties of the samples with and without nano-TiN addition fabricated by PIM and die pressing were analyzed. It is demonstrated that for either PIM or die pressing, the porosities are obviously reduced, the mechanical properties are significantly improved after adding nano-TiN, and the hard particles are refined; the rim phase thickness obviously becomes thinner, and the number of dimples in fracture also increases. Compared the samples fabricated by die pressing, it is difficult for PIM to obtain dense Ti（C,N）-based cermets. Due to the too much existence of pores and isolated carbon, the mechanical properties of the sintered samples by PIM are inferior to those of the sintered ones by die pressing.

Optimization strategy in end milling process for high speed machining of hardened die/mold steel

An optimization strategy for high speed machining of hardened die/mold steel based on machining feature analysis was studied. It is a further extension of the previously presented study on the thermal mechanism of end milling and constant cutting force control. An objective function concerning machining cost and associated optimization algorithm based on machining time and cutting length calculation was proposed. Constraints to satisfy specific machining strategies when high speed machining the hardened die/mold steel, trochoid tool path pattern in slot end milling to avoid over-heat and feed rate adaptation to avoid over-load, were also discussed. As a case study, the tool selection problem when machining a die part with multiple machining features was investigated.

HSM strategy study for hardened die and mold steels manufacturing based on the mechanical and thermal load reduction strategy

The paper discussed cutter-work engagement situation hidden behind the mechanical and thermal load effect on cutting edges during high speed hard machining process. The engagement situation was investigated in great detail using experimental and geometrical analytic measures. Experiments were conducted using A1TiN-coated micro-grain carbide end mill cutters to cut hardened die steel. On the basis, a general high speed hard machining strategy, which aimed at eliminating excessive engagement situation during high-speed machining （HSM） hard machining, was proposed. The strategy includes the procedures to identify prone-to-overload areas where excessive engagement situation occurs and then to create a reliable tool path, which has the effect of cutting load reduction to remove the prone-to-overload areas.

A Tool Path Re-generation Algorithm for Die & Mold Machining

Facing the challenges of a shorter product design a nd manufacturing lead-time, many mold companies are using 3-D CAD/CAM software s ystems in design and manufacturing. A new product file is often issued to the mo ld design department before it is completely finalized and the design may have t o be iterated many times during the mold design and making processes. In practic e, if a mold has been modified, all the tool paths that cover the modified regio n must be re-generated, no matter how small the modified region may be. With th e available tool path generation systems, if a tool path needs to be re-generat ed, all the cutter location (CL) points must be re-calculated, and none of the original CL points can be re-used. It would require as much time to re-gen erate the modified tool path as in the original case. On the other hand, the mod ified region is usually quite small compared with the entire mold. The complete re-generation process is therefore highly unproductive and time-consuming. This paper proposes an efficient tool path re-generation approach for 3-axis d ie and mold machining. It is assumed in this research that a gouge-free too l path has been generated for the original mold and the same ball end-mill is to be used to generate the tool path for the modified mold. It is shown in th is work that if the boundary of the modified region is interference-free, the a ffected CL points are enclosed by a set of CL points which correspond to the poi nts on the boundary of the modified region. An efficient tool path re-generatio n algorithm was developed in this research. With this algorithm, a closed CL cur ve is first generated from the boundary of the affected region. The CL points fo r the original mold are then analyzed by comparing the x and y values with the b oundary of the affected CL points. If the CL points are not affected by the modi fication, they are output to the new CL file directly. Otherwise, they are remov ed and replaced by the new CL points. The algorithm has been tested using severa l industrial parts, and results show that it is efficient, robust, and the re-g enerated tool path is gouge-free and smooth.

Development of Online Machining and Measurement System in Die and Mold Manufacturing： Concept and Fundamental Experiments

The corrective machining to compensate the resulting errors is usually tried at plural times based on the trial-and-error process when the machining is realized in die and mold manufacturing. This corrective machining has an influence on accuracy and efficiency and is an important factor. The measurement system for measuring the forms of die and mold at all times is essential in order to machine the die and mold with high accuracy and efficiency. However, the problems of management and operation errors are found in compensating process of die and mold machining. In this paper, an online machining and measurement system in die and mold manufacturing is developed in order to overcome these problems. In this online system, 2-axis control system is added to a surface roughness measuring instrument, and both NC machining program and measured data are linked and controlled using a same computer. Therefore, the machining and measurement can be recognized for consistent process, and can be realized on the machine. This system has the advantages such as the high accuracy, low-price, and online convenience and so on. The possibility of practical use of this online system was investigated by fundamental experiments.

Polishing Techniques of Stainless Steel Molding Die for the Slumping Method of Glass Optical Components

In recent years, high precision geometric shape, surface roughness, and cost reduction are required for large glass component molding processes. In this research, the polishing process of stainless steel molding dies used to form thin glass components is investigated. The surface roughness of the polished stainless steel molding die surface is below Rz = 200 nm （P-V） at 15 h polishing with 0.5 % alumina polishing liquid. In the case of polishing process with only the weight of molding die and a polishing pressure of 0.5 kPa, polishing times are approximately 60 h and 20 h, respectively. Final surface roughness polished stainless steel molding die surface with pressure of 0.5 kPa is Rz = 7 nm （P-V）, rms -- 1.6 nm and Ra = 1.4 nm. In a thin glass component manufacturing method, ＂slumping method＂, surface roughness before glass forming is rms = 0.7 nm and Ra = 0.6 nm, and after is rms = 0.7 nm and Ra = 0.6 nm. Therefore, there were no observable changes their surface roughness.

Approach Based on Response-Surface Method to Optimize Lining of Dies Used in 3D Free-Bending Forming Technology

In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of the forming die lining.However,the effects of die-lining structural parameters on the tube quality,and a method to determine the combination of die-lining structural parameters is yet to be devised.This study aims to propose a new framework that allows one to understand the effects of various die-lining structural parameters on tube quality and to propose the best combination of die-lining structural parameters.First,finite-element modeling is performed to simulate 3D-FBF and examine the effects of individual die-lining structures on the quality of tube formation.The simulation results show that the deformation-zone length and die gap are positively correlated with the tube-section distortion and wall-thickness variation,whereas it shows an opposite trend with respect to the bending radius.Additionally,the lining chamfer radius of the bending die and the guide lining chamfer radius minimally affect the tube forming quality.Subsequently,the optimal die-lining structure is obtained using the response-surface method.The tube cross-sectional distortion rate reduced from 2.73 to 2.53%after the die lining is optimized.Additionally,the average inner-wall thickness reduced to 1.06 mm,whereas the average outer-wall thickness increased to 0.97 mm.This paper proposes a method for optimizing the forming-die-lining mechanism and for improving the tube forming quality in 3D-FBF.

基于Moldflow对突变壁厚塑件的注塑成型优化方案的研究

利用Mold flow/MPI技术对摩托车外壳进行CAE注塑模拟分析,预测了成型过程中的填充流动情况,并对型腔的填充时间、压力分布、锁模力大小等进行计算分析,掌握了翘曲变形产生的原因。根据注塑模拟分析结果优化了浇口、冷却系统设计方案和成型工艺参数,使模具设计更趋合理。优化后的成型方案用于实际生产,缩短了试模周期。

MOLDFLOW软件在塑料成型工艺与模具设计教学中的应用

简要介绍了MOLDFLOW软件,分析了塑料成型工艺与模具设计课程的特点,重点阐述了MOLDFLOW软件在塑料成型工艺与模具设计教学中的应用,帮助学生理解和掌握本课程教学中的重点、难点内容,有效地提高了学生的科研能力和教学效果。

Study on Numerical Simulation of Mold Filling and Solidification Processes under Pressure Conditions

The mold filling and solidification simulation for the high pressure die casting (HPDC) and low pressure die casting (LPDC) processes were studied. A mathematical model considering the turbulent flow and heat transfer phenomenon during the HPDC process has been established and parallel computation technique was used for the mold filling simulation of the process. The laminar flow characteristics of the LPDC process were studied and a simplified model for the mold filling process of wheel castings has been developed. For the solidification simulation under pressure conditions, the cyclic characteristics and the complicated boundary conditions were considered and techniques to improve the computational efficiency are discussed. A new criterion for predicting shrinkage porosity of Al alloy under low pressure condition has been developed in the solidification simulation process.

基于Pro/Moldesign和EMX的缸盖罩压铸模具设计

在分析铸件工艺的基础上,用Pro/E的Moldesign模块完成了模具主体部分的设计,并用专家模架系统EMX完成了模架的设计。EMX的运用,省去了以往设计铸模后再逐个设计模架组件的繁琐工作,结合通用模具设计模块Pro/Moldesign,大大提高了模具设计的效率。模具动画仿真结果,验证了所设计缸盖罩压铸模具的合理性。

Moldflow软件对轿车水箱盖注射成型模具温度的优化

用Moldflow软件优化轿车水箱盖注射成型的模具温度。结果表明:模具温度在175℃时,胶料充模时间短,充模结束时的体积固化率小,充模后35 s时的体积固化率大。Moldflow软件可以优化橡胶制品的注射成型工艺,缩短工艺和模具设计周期,提高生产效率和产品质量。

基于UG与MOLDFLOW双分型小水口注塑模设计

以按键板塑件为例,改变以往经验传承及试模的设计方式,通过应用数值模拟技术,预测了熔接痕、翘曲变形等注塑缺陷对塑件成型质量的影响,提出浇注系统优化方案,并验证了方案的合理性,确定了双分型小水口的结构形式,最后基于UG与MOLDFLOW分析结果进行注塑模总体设计,生产实践证明该模具结构灵活可靠,产品符合要求。