Publicação
Modelling and simulation of die casting process in aluminium alloys
| Resumo: | In today's modern world, the need for increased production to meet demand is ever-present. However, due to time constraints, the primary focus is on boosting productivity and minimizing time-consuming tasks. By doing so, better solutions can be found, or the intrinsic costs of processes can be reduced. The Die Casting technology is no exception to this requirments. The time the engineers spent in the development and validation of gating design remains one of the bottlenecks of the process. Therefore, a solution must be found in order to improve the modelling and simulation of the die casting process. This dissertation explores the potential of using Python as a programming tool for the gating design in die casting manufacturing. The knowledge gained has been compiled into software named Highly Efficient Labor-saving Program Die Casting. This software can accommodate various casting alloys, it emphasizes aluminum alloys. The software was applied at two stages of gating design validation. First, it was used to generate the gating design, overflow, and venting system for a valve cover, along with the corresponding dimensional data for each section. Second, it was employed during the die casting process simulation to calculate the boundary conditions and initial conditions. The validation of the gating designs focused on three key aspects: die cycle simulation to ensure a stable thermal gradient, analysis of potential defects (such as shrinkage porosity, air entrainment, and cold shuts), and an evaluation of the process dynamics (based on the minor and major losses of the molten metal). In the process dynamics analysis, two distinct phases were identified where the losses behaved differently. |
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| Autores principais: | Duro, Nélson Moura Pereira |
| Assunto: | Programming aided design High-pressure die casting process Aluminum alloys Finite differences method Modelação assistida por programas Processo de fundição injetada Ligas de alumínio Método das diferenças finitas |
| Ano: | 2024 |
| País: | Portugal |
| Tipo de documento: | dissertação de mestrado |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Universidade do Minho |
| Idioma: | inglês |
| Origem: | RepositóriUM - Universidade do Minho |
| Resumo: | In today's modern world, the need for increased production to meet demand is ever-present. However, due to time constraints, the primary focus is on boosting productivity and minimizing time-consuming tasks. By doing so, better solutions can be found, or the intrinsic costs of processes can be reduced. The Die Casting technology is no exception to this requirments. The time the engineers spent in the development and validation of gating design remains one of the bottlenecks of the process. Therefore, a solution must be found in order to improve the modelling and simulation of the die casting process. This dissertation explores the potential of using Python as a programming tool for the gating design in die casting manufacturing. The knowledge gained has been compiled into software named Highly Efficient Labor-saving Program Die Casting. This software can accommodate various casting alloys, it emphasizes aluminum alloys. The software was applied at two stages of gating design validation. First, it was used to generate the gating design, overflow, and venting system for a valve cover, along with the corresponding dimensional data for each section. Second, it was employed during the die casting process simulation to calculate the boundary conditions and initial conditions. The validation of the gating designs focused on three key aspects: die cycle simulation to ensure a stable thermal gradient, analysis of potential defects (such as shrinkage porosity, air entrainment, and cold shuts), and an evaluation of the process dynamics (based on the minor and major losses of the molten metal). In the process dynamics analysis, two distinct phases were identified where the losses behaved differently. |
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