Parametric Study for Runner Modifications of Die Casted Part with Venting Systems

High-pressure die casting (HPDC) is a process used for creating complex components by injecting the molten metal inside the cavity at high pressure. Failure in die casting may reduce product mechanical properties, surface quality, and life cycle. In this paper, the die-casting process of an inspection instrument – test piece is investigated for parametric study and Computational fluid dynamics (CFD) analysis. Parameters used in the die-casting process are important since it affects the molten flow quality inside the cavity. Thus, a parametric study is done to investigate the optimum parameter use in the die-casting process of the test piece. Runner gating system design is also one of the important criteria to maintain the quality of products. This paper also investigated the effect of runner gating system design optimization in reducing gas porosity. The CT scan of the sample mold is included to compare the relationships between gas porosity occurrence with CFD results. This paper proposed a new runner design named outward curvature runner with an air vent that can improve velocity and temperature distributions in reducing die-casting defects. In addition to that, air vents are installed to extend the volume and promote higher suction, to eliminate gas bubbles entrapment inside the cavity

Parametric Study for Runner Modifications of Die Casted Part with Venting Systems

High-pressure die casting (HPDC) is a process used for creating complex components by injecting the molten metal inside the cavity at high pressure. Failure in die casting may reduce product mechanical properties, surface quality, and life cycle. In this paper, the die-casting process of an inspection instrument – test piece is investigated for parametric study and Computational fluid dynamics (CFD) analysis. Parameters used in the die-casting process are important since it affects the molten flow quality inside the cavity. Thus, a parametric study is done to investigate the optimum parameter use in the die-casting process of the test piece. Runner gating system design is also one of the important criteria to maintain the quality of products. This paper also investigated the effect of runner gating system design optimization in reducing gas porosity. The CT scan of the sample mold is included to compare the relationships between gas porosity occurrence with CFD results. This paper proposed a new runner design named outward curvature runner with an air vent that can improve velocity and temperature distributions in reducing die-casting defects. In addition to that, air vents are installed to extend the volume and promote higher suction, to eliminate gas bubbles entrapment inside the cavity

Relationship Between Heat and Troughs During a Transport Process of Heating the Pet Films

Understanding the troughs caused during a heat treatment process is important for ensuring process stability and product quality in roll-to-roll (R2R) productions methodology. The purpose of this study is to confirm the relationship between heat and troughs during a transport process of heating where heat is applied over a wide range of area. The temperature and tension applied to the web during the heated transport process were measured in the experimental analysis. Results showed that the web were stretched in the web transport direction during the heat transfer process. However, troughs did not occur because the experiment was conducted below the glass transition temperature. The comparison between the web temperature obtained in the experimental analysis with the one-dimensional thermal conduction simulation for the temperature distribution of the web are also conducted in this paper. This simulation was performed using a non-Fourier model that can be used on microscales. Simulation results show that when the temperature is gradually raised, the amount of thermal conduction is reduced during transportation of the web. The thermal conduction of ballistic phonon is smaller than that of the diffuse phonon when compared at same distance. Even though there were differences between the experimental values and the simulation results, this is because it ignores the heat transfer and radiant heat transfer

Relationship Between Heat and Troughs During a Transport Process of Heating the Pet Films

Understanding the troughs caused during a heat treatment process is important for ensuring process stability and product quality in roll-to-roll (R2R) productions methodology. The purpose of this study is to confirm the relationship between heat and troughs during a transport process of heating where heat is applied over a wide range of area. The temperature and tension applied to the web during the heated transport process were measured in the experimental analysis. Results showed that the web were stretched in the web transport direction during the heat transfer process. However, troughs did not occur because the experiment was conducted below the glass transition temperature. The comparison between the web temperature obtained in the experimental analysis with the one-dimensional thermal conduction simulation for the temperature distribution of the web are also conducted in this paper. This simulation was performed using a non-Fourier model that can be used on microscales. Simulation results show that when the temperature is gradually raised, the amount of thermal conduction is reduced during transportation of the web. The thermal conduction of ballistic phonon is smaller than that of the diffuse phonon when compared at same distance. Even though there were differences between the experimental values and the simulation results, this is because it ignores the heat transfer and radiant heat transfer

Analysis of Fractures and Microstructures on Different Injection Speeds in High-Pressure Die-Casting Magnesium Alloy

In this study, to clarify the unknown physical properties of the Mg-Al-Th-RE alloy, the relationship between the injection conditions and the internal porosities, and the mechanical properties exerted by the solidification microstructure was investigated. The obtained cast samples were investigated using X-ray CT internal measurements, tensile tests, Vickers hardness tests, and solidification microstructure observations. The tensile strength and the elongation at the injection speed of 5.0 m/s were higher than at 2.0 m/s. The number of porosities affected the tensile strength and the elongation even at the same fracture position. In addition, it was confirmed that segregation affected the destruction smaller the porosity size and the greater the variability of porosity. As the injection speed increased, the amount of heat transferred between the molten metal and the wall surface also increased, resulting in quick freezing and solidification. The tensile strength increased at the injection speed of 5.0 m/s because the interface between the scattered primary crystals and eutectic systems was narrow. On the other hand, at the injection speed of 2.0 m/s, the tensile strength decreased because the molten metal was delayed in solidification and dendrite growth became remarkable

Analysis of Fractures and Microstructures on Different Injection Speeds in High-Pressure Die-Casting Magnesium Alloy

In this study, to clarify the unknown physical properties of the Mg-Al-Th-RE alloy, the relationship between the injection conditions and the internal porosities, and the mechanical properties exerted by the solidification microstructure was investigated. The obtained cast samples were investigated using X-ray CT internal measurements, tensile tests, Vickers hardness tests, and solidification microstructure observations. The tensile strength and the elongation at the injection speed of 5.0 m/s were higher than at 2.0 m/s. The number of porosities affected the tensile strength and the elongation even at the same fracture position. In addition, it was confirmed that segregation affected the destruction smaller the porosity size and the greater the variability of porosity. As the injection speed increased, the amount of heat transferred between the molten metal and the wall surface also increased, resulting in quick freezing and solidification. The tensile strength increased at the injection speed of 5.0 m/s because the interface between the scattered primary crystals and eutectic systems was narrow. On the other hand, at the injection speed of 2.0 m/s, the tensile strength decreased because the molten metal was delayed in solidification and dendrite growth became remarkable

Relationship Between Heat and Troughs During a Transport Process of Heating the Pet Films

Understanding the troughs caused during a heat treatment process is important for ensuring process stability and product quality in roll-to-roll (R2R) productions methodology. The purpose of this study is to confirm the relationship between heat and troughs during a transport process of heating where heat is applied over a wide range of area. The temperature and tension applied to the web during the heated transport process were measured in the experimental analysis. Results showed that the web were stretched in the web transport direction during the heat transfer process. However, troughs did not occur because the experiment was conducted below the glass transition temperature. The comparison between the web temperature obtained in the experimental analysis with the one-dimensional thermal conduction simulation for the temperature distribution of the web are also conducted in this paper. This simulation was performed using a non-Fourier model that can be used on microscales. Simulation results show that when the temperature is gradually raised, the amount of thermal conduction is reduced during transportation of the web. The thermal conduction of ballistic phonon is smaller than that of the diffuse phonon when compared at same distance. Even though there were differences between the experimental values and the simulation results, this is because it ignores the heat transfer and radiant heat transfer

Parametric Study for Runner Modifications of Die Casted Part with Venting Systems

High-pressure die casting (HPDC) is a process used for creating complex components by injecting the molten metal inside the cavity at high pressure. Failure in die casting may reduce product mechanical properties, surface quality, and life cycle. In this paper, the die-casting process of an inspection instrument - test piece is investigated for parametric study and Computational fluid dynamics (CFD) analysis. Parameters used in the diecasting process are important since it affects the molten flow quality inside the cavity. Thus, a parametric study is done to investigate the optimum parameter use in the die-casting process of the test piece. Runner gating system design is also one of the important criteria to maintain the quality of products. This paper also investigated the effect of runner gating system design optimization in reducing gas porosity. The CT scan of the sample mold is included to compare the relationships between gas porosity occurrence with CFD results. This paper proposed a new runner design named outward curvature runner with an air vent that can improve velocity and temperature distributions in reducing die-casting defects. In addition to that, air vents are installed to extend the volume and promote higher suction, to eliminate gas bubbles entrapment inside the cavity