Publicação
Gating design of a bathtub body in brass alloy cast by low-pressure die casting
| Resumo: | In manufacturing, Low-Pressure Die Casting (LPDC) has stood out as a versatile and innovative solution, notably recognized in various sectors, particularly in the production of taps. Due to its ability to produce high-quality castings with minimal waste, this technology has gained significant prominence today. However, foundries face several challenges, mainly related to inadequate casting designs, resulting in defects that lead to the rejection of components. Addressing this issue, the present dissertation provides a transparent and objective description of the development of a filling system applied to the LPDC, using simulation software (QuikCAST) to reduce the occurrence of defects. Chapter 1 introduces the current problem observed in casting simulations, along with the objective of the work - the development of a filling system through numerical simulation. Additionally, a brief overview of the document's structure is provided. Chapter 2 describes the casting technology employed, Low-Pressure Die Casting, covering its sequence and highlighting prevalent defects. The copper alloy and the mould material used in this work are described in Chapter 3. This chapter covers the most significant characteristics of each material for the numerical simulation. Chapter 4 describes the numerical simulation process used in the QuikCAST software, with two types of simulation being used: Thermal Die Cycling to determine the temperature of dies and Filling Process simulation. This chapter also presents the study case used in the dissertation (bathtub water mixer) and all considerations regarding core design and the filling system. The main focus of this work is Chapter 5, with three candidate solutions being proposed to reduce the high rejection rate of parts. Each solution was carefully designed, considering the key aspects of casting filling systems development. Simulation played a crucial role, allowing the prediction and evaluation of the proposed systems. The selected solution demonstrated overall positive results, including a high casting yield (60%), a low defect percentage, and no air inside the cavity. These outcomes indicate a reduced rejection rate of cast parts and improvement in the company's production process. Chapter 6 summarizes the entire project, providing an overview of the work and offering insights for future research. In a broader context, this project demonstrated the feasibility of implementing simulation software in foundries to reduce costs and time-to-market. |
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| Autores principais: | Oliveira, Helena Sofia Cardoso |
| Assunto: | Casting simulation Low-pressure die casting Defects prediction Quikcast Brass Simulação de fundição Fundição por baixa pressão Previsão de defeitos Quikcast Latão |
| Ano: | 2023 |
| 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 manufacturing, Low-Pressure Die Casting (LPDC) has stood out as a versatile and innovative solution, notably recognized in various sectors, particularly in the production of taps. Due to its ability to produce high-quality castings with minimal waste, this technology has gained significant prominence today. However, foundries face several challenges, mainly related to inadequate casting designs, resulting in defects that lead to the rejection of components. Addressing this issue, the present dissertation provides a transparent and objective description of the development of a filling system applied to the LPDC, using simulation software (QuikCAST) to reduce the occurrence of defects. Chapter 1 introduces the current problem observed in casting simulations, along with the objective of the work - the development of a filling system through numerical simulation. Additionally, a brief overview of the document's structure is provided. Chapter 2 describes the casting technology employed, Low-Pressure Die Casting, covering its sequence and highlighting prevalent defects. The copper alloy and the mould material used in this work are described in Chapter 3. This chapter covers the most significant characteristics of each material for the numerical simulation. Chapter 4 describes the numerical simulation process used in the QuikCAST software, with two types of simulation being used: Thermal Die Cycling to determine the temperature of dies and Filling Process simulation. This chapter also presents the study case used in the dissertation (bathtub water mixer) and all considerations regarding core design and the filling system. The main focus of this work is Chapter 5, with three candidate solutions being proposed to reduce the high rejection rate of parts. Each solution was carefully designed, considering the key aspects of casting filling systems development. Simulation played a crucial role, allowing the prediction and evaluation of the proposed systems. The selected solution demonstrated overall positive results, including a high casting yield (60%), a low defect percentage, and no air inside the cavity. These outcomes indicate a reduced rejection rate of cast parts and improvement in the company's production process. Chapter 6 summarizes the entire project, providing an overview of the work and offering insights for future research. In a broader context, this project demonstrated the feasibility of implementing simulation software in foundries to reduce costs and time-to-market. |
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