New trends in cold-chamber die casting machine design

Larger and larger proportions of aluminium castings,especially those produced by the die casting process,can be observed during recent years in the automotive industry,house-hold articles and others.In case of the automotive industry,apart from the traditional elements produced by the die pressure method such as engine blocks or crank shaft bedplates,aluminium is displacing steel from structural parts of cars('body in white').The current state and development directions of the structural solutions of cold-chamber die castings are analysed in this paper.These solutions drive the prospective development of these machines and die casting technology.The focus is mainly on essential functional systems such as:hydraulic drives of closing and locking units,as well as pressing in die machines of known companies present on the European market.

A Dual Closed-Loop Digital Twin Construction Method for Optimizing the Copper Disc Casting Process

The copper disc casting machine is core equipment for producing copper anode plates in the copper metallurgy industry.The copper disc casting machine casting package motion curve(CPMC) is significant for precise casting and efficient production.However,the lack of exact casting modeling and real-time simulation information severely restricts dynamic CPMC optimization.To this end,a liquid copper droplet model describes the casting package copper flow pattern in the casting process.Furthermore,a CPMC optimization model is proposed for the first time.On top of this,a digital twin dual closed-loop self-optimization application framework(DT-DCS) is constructed for optimizing the copper disc casting process to achieve self-optimization of the CPMC and closed-loop feedback of manufacturing information during the casting process.Finally,a case study is carried out based on the proposed methods in the industrial field.

COMPUTER CONTROL SYSTEM FOR DRAWING MACHINE IN HORIZONTAL CONTINUOUS CAST SET

A computer control system for drawing machine in horizontal continuous cast set was introduced.The operation features of the drawing machine were analyzed»the hardware configuration and principles of interface circuit for stroke measurements were given out.An effective method was provided,which made the process parameters progressively optimize under the software environment using friendly interface of person-and-computer communication.This method was also adaptable to optimize parameters of other production process which are hard to model.

基于AnyCasting的机床床身铸造工艺计算机仿真与优化

以常规的机床床身铸造工艺为基础,借助AnyCasting软件对其铸造过程进行仿真分析,探究了工艺参数对铸件品质的影响规律。获得的优化工艺参数组合为:充型温度1300℃,充型速度1.7 m/s,冷铁厚度70 mm。以优化的工艺参数制备出品质良好的铸件。

基于AnyCasting的机床滑块铸造模拟及工艺优化

采用铸造模拟软件Any Casting对球墨铸铁机床滑块铸件进行充型、凝固过程模拟。根据铸件金属液的凝固规律,分析出缺陷的分布;通过增大冒口和添加冷铁,改进了工艺方案。模拟结果表明,工艺改进后铸件导轨处的凝固时间明显缩短,顶部缩松缩孔缺陷被完全消除。该研究对同类铸件的工艺设计具有一定的参考价值和指导意义。

Effect of inoculating addition on machinability of gray cast iron

Gray cast irons were inoculated with FeSi75＋RE and FeSi75＋Sr inoculants. The changes of apex angle of the drills before and after being used were used to evaluate machinability of gray cast irons. Effect of FeSi75＋RE and FeSi75＋Sr inoculants on mechanical properties, machinability and sensibility of gray cast iron used in cylinder block were investigated. Experimental results showed that gray cast iron treated with 60%FeSi75＋40% RE inoculants exhibited tensile strength consistently at about 295 MPa along with good hardness and improved metallurgical quality. While gray cast iron inoculated with 20%FeSi75＋80% Sr inoculants exhibited the best machinability, the lowest cross-section sensibility and the least microhardness difference. The tool flank wear of the drill increased correspondingly with the increase of the microhardness difference of the matrix, indicating the great effect of homogeneity of the matrix on the machinability of gray cast iron.

Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing

Silicon-based aluminum casting alloys are known to be one of the most widely used alloy systems mainly due to their superior casting characteristics and unique combination of mechanical and physical properties. However,manufacturing of thin-walled aluminum die-casting components,less than 1.0 mm in thickness,is generally known to be very difficult task to achieve aluminum casting alloys with high fluidity.Therefore,in this study,the optimal die-casting conditions for producing 297 mm×210 mm×0.7 mm thin-walled aluminum component was examined experimentally by using 2 different gating systems,tangential and split type,and vent design.Furthermore,computational solidification simulation was also conducted.The results showed that split type gating system was preferable gating design than tangential type gating system at the point of view of soundness of casting and distortion generated after solidification.It was also found that proper vent design was one of the most important factors for producing thin-wall casting components because it was important for the fulfillment of the thin-wall cavity and the minimization of the casting distortion.

Survey of the 4th China International Diecasting Exhibition

Die casting machines, dies, die castings, peripheral equipments, die lubricants, raw materials for die casting, melting & holding furnaces, cleaning equipments, etc. were exhibited during the 4th China International Die Casting Exhibition, which was surveyed in the paper.

Machine Learning-Based Research on Tensile Strength of SiC-Reinforced Magnesium Matrix Composites via Stir Casting

SiC is the most common reinforcement in magnesium matrix composites,and the tensile strength of SiC-reinforced magnesium matrix composites is closely related to the distribution of SiC.Achieving a uniform distribution of SiC requires fine control over the parameters of SiC and the processing and preparation process.However,due to the numerous adjustable parameters,using traditional experimental methods requires a considerable amount of experimentation to obtain a uniformly distributed composite material.Therefore,this study adopts a machine learning approach to explore the tensile strength of SiC-reinforced magnesium matrix composites in the mechanical stirring casting process.By analyzing the influence of SiC parameters and processing parameters on composite material performance,we have established an effective predictive model.Furthermore,six different machine learning regression models have been developed to predict the tensile strength of SiC-reinforced magnesium matrix composites.Through validation and comparison,our models demonstrate good accuracy and reliability in predicting the tensile strength of the composite material.The research findings indicate that hot extrusion treatment,SiC content,and stirring time have a significant impact on the tensile strength.

A Multi-Objective Hybrid Algorithm for the Casting Scheduling Problem with Unrelated Batch Processing Machine

The casting production process typically involves single jobs and small batches,with multiple constraints in the molding and smelting operations.To address the discrete optimization challenge of casting production scheduling,this paper presents a multi-objective batch scheduling model for molding and smelting operations on unrelated batch processing machines with incompatible job families and non-identical job sizes.The model aims to minimise the makespan,number of batches,and average vacancy rate of sandboxes.Based on the genetic algorithm,virus optimization algorithm,and two local search strategies,a hybrid algorithm(GA-VOA-BMS)has been designed to solve the model.The GA-VOA-BMS applies a novel Batch First Fit(BFF)heuristic for incompatible job families to improve the quality of the initial population,adopting the batch moving strategy and batch merging strategy to further enhance the quality of the solution and accelerate the convergence of the algorithm.The proposed algorithm was then compared with multi-objective swarm optimization algorithms,namely NSGA-ll,SPEA-l,and PESA-ll,to evaluate its effectiveness.The results of the performance comparison indicate that the proposed algorithm outperforms the others in terms of both qualityand stability.

基于ProCAST轴座砂型铸造数值模拟研究

根据企业铸造过程的原始工艺,利用三维ProCAST软件建立轴座铸件浇注系统模型,并对铸造充型和凝固过程进行模拟,观察温度场和流场的变化情况,预测铸造缺陷的位置。对模拟结果进行分析,并改进初始工艺方案。对优化后的不同方案进行模拟分析,结果表明,通过改变浇注位置,将底注式改为顶注式能使金属液有效充满型腔,且增加冷铁能有效地加快热节处金属液的冷却速度,从而减少缩孔、缩松等缺陷,提高铸件质量。利用振动铸造机对铸造过程施加振动,验证了多维振动有助于提高金属液的充型能力。

机床底座ProCAST数值模拟及铸造工艺优化

中型灰铸铁机床底座铸造过程中,补缩不足使铸件厚大部分产生较大缩松缩孔,用Creo进行机床底座3D建模,通过3D打印制作分析模型;用ProCAST软件对充型与凝固过程进行多方案、多次有限元分析及仿真模拟。结果表明:铸件厚大部位易产生热节,冷却后产生缩松缩孔,用增加冒口与铺设冷铁等方案优化铸造工艺,使铸件自然补缩,最终实现自下而上的顺序凝固,有效避免产生较大热节,解决了铸件的缩松缩孔缺陷。

Numerical Simulation and Analysis of Residual Stress in Machine Tool Bed Casting

A combined FDM/FEM software system was developed to analyze the temperature and stress distributions in castings. The FDM was used to calCulate the temperature distribution while the FEM was used for the stresssimulation. For practical application, a machine tool bed iron casting was selected and the high temperature mechanical properties of the cast iron were measured. The FDM/FEM simulation results of the temperature and stressdistributions of the solidification process of the casting using current production technology agreed well with the measured temperature and residual stress results. A modified production technology was then proposed. The numericalsimulation results showed that the temperature distribution of the modified production technology was more uniformand the distribution and value of residual stresses were more favorable to dimensional stability of the machine tool.

基于PROCAST软件的铸锭形状仿真分析

目前对于硅锰合金的主流生产方式为坑池铸造,但该方法易产生严重粉尘污染并造成资源浪费.为了解决该问题,当前硅锰合金行业设计并制造了一种连铸粒化设备,利用锭模铸造方法加工硅锰合金,能够有效减少污染、节约材料并提高生产效率.为了对锭模铸造方法进行更全面的认识,利用PROCAST仿真软件,对半球体和半球圆柱体铸锭的铸造进行仿真,计算了不同形状的型腔在不同材料的模具上的孔隙率,分析了铸锭的形状对不同材料的模具上浇铸结果的影响.

Optimization of electrical discharge machining process parameters for Al6061/cenosphere composite using grey-based hybrid approach

Fly ash has congregated considerable attention as a potential reinforcement for aluminum matrix composites(AMCs)to enhance selective properties and reduce the cost of fabrication.However,poor machinability of such AMCs limits their application.The present study focuses on the preparation of cenosphere fly ash reinforced Al6061alloys by compo casting method.X-ray diffraction analysis of the prepared AMCs exposes the presence of cenosphere particles without any formation of other intermetallic compounds.In this study,electrical discharge machining(EDM)was engaged to examine the machinability of the prepared metal matrix composite(MMCs).The measured performance characteristics for the various combinations of input process parameters were considered to be MRR,EWR and SR.Face centered central composite design(CCD)of response surface method(RSM)was employed to design the number of experimental trials required and a hybrid approach of grey-based response surface methodology(GRSM)was imposed for predicting the optimal combination of processing parameter in EDM process.Generous improvement was observed in the performance characteristics obtained by employing both the optimal setting of machining parameters.The optical3D surface profile graphs of the ED machined surface also revealed the improvement in surface quality and texture employing the optimal processing conditions proposed by hybrid GRSM approach.

宝钢集团五钢公司Concast特殊钢方坯连铸机的特点及其完善

介绍了宝钢集团五钢有限公司引进的Concast特殊钢方坯连铸机的技术特性。

An energy consumption prediction approach of die casting machines driven by product parameters

Die casting machines,which are the core equipment of the machinery manufacturing industry,consume great amounts of energy.The energy consumption prediction of die casting machines can support energy consumption quota,process parameter energy-saving optimization,energy-saving design,and energy efficiency evaluation;thus,it is of great significance for Industry 4.0 and green manufacturing.Nevertheless,due to the uncertainty and complexity of the energy consumption in die casting machines,there is still a lack of an approach for energy consumption prediction that can provide support for process parameter optimization and product design taking energy efficiency into consideration.To fill this gap,this paper proposes an energy consumption prediction approach for die casting machines driven by product parameters.Firstly,the system boundary of energy consumption prediction is defined,and subsequently,based on the energy consumption characteristics analysis,a theoretical energy consumption model is established.Consequently,a systematic energy consumption prediction approach for die casting machines,involving product,die,equipment,and process parameters,is proposed.Finally,the feasibility and reliability of the proposed energy consumption prediction approach are verified with the help of three die casting machines and six types of products.The results show that the prediction accuracy of production time and energy consumption reached 91.64%and 85.55%,respectively.Overall,the proposed approach can be used for the energy consumption prediction of different die casting machines with different products.

基于ProCAST的悬梁铸造模拟及工艺优化

利用ProCAST对机床悬梁的铸造工艺进行数值模拟分析,根据铸件充型和凝固的温度场、充型时间及缺陷分布,对初始铸造工艺进行优化。结果表明,铸件浇注时间为35 s,初始方案中,原因是由于壁厚较大而导致冷却缓慢,使得金属液向先凝固的地方进行了补缩,导轨部分出现了较大面积的缩松、缩孔缺陷。通过在铸件侧表面施加6个侧冒口和顶部施加4个顶缩颈冒口进行补缩,在导轨面添加17块冷铁以激冷的方式减少铸件缩孔缩松问题。仿真结果表明,优化工艺有效抑制了铸件缩孔缩松的形成,提高了铸件质量,对悬梁的生产起到指导性作用。

Study on Simulation of 5-axis NC Machining Process

Ray-casting technique used to generate realism graphs is creatively applied to simulate the NC machining process of an integral turbo-wheel, thus the representation of a workpiece is redused from 3D to 1D. As a result, simulation speed is raised greatly and the visualization is kept. The relative problems are the discussed in detail and the 5 - axis NC machining process simulation of integral turbo-wheel is illustrated with Ray-casting representation.