A Systematic Approach for Computer-Aided Gating-System Design for Die Casting Dies

2016 ◽  
Author(s):  
Ranjit Singh ◽  
Rajesh Kumar ◽  
Jatinder Madan
Keyword(s):  
Die Casting ◽  
Casting Machine ◽  
Die Design ◽  
Gating System ◽  
Process Data ◽  
Industrial Case Study ◽  
Die Casting Die ◽  
Computer Aided ◽  
System Feature

Multi-gates are often used in the die-casting die design to provide proper feed of the molten metal to the cavity for obtaining a sound casting. Although a number of systems for design of gating-systems are available they do not help much to design multi-gates. A computer aided system for gating-system for die-casting die-design with multi-gates is proposed in this paper. The proposed system helps to generate parameters of the multi-cavity die taking into account a multitude of factors, such as part design, material properties, process data and die-casting machine information. The parameters so generated are applied on selected gating-system feature existing in the library to complete the design of gating-system. The system generated results for industrial case-study parts are in tandem with the industry practices. The proposed system would greatly help bridge the existing gaps between design and manufacturing for die-casting die-design.

A system for computer-aided gating design for multi-cavity die-casting dies

2015 ◽  
Vol 231 (11) ◽  
pp. 1983-1999 ◽  
Author(s):  
Vijay Kumar ◽  
Jatinder Madan
Keyword(s):  
System Design ◽  
Computer Aided Design ◽  
Die Casting ◽  
Casting Process ◽  
Manufacturing Cost ◽  
Gating System ◽  
Industrial Case Study ◽  
Efficient Manner ◽  
Die Casting Die ◽  
Computer Aided

The gating system design for a die-casting die is a non-trivial task that involves a number of steps and computations, in which many factors related to part design, material, and process need to be accounted. In case of a multi-cavity die-casting die, the non-triviality of the gating system design increases manifold. The main contribution of this article is to develop a computer-aided system for design of gating system for multi-cavity die-casting dies. The proposed system applies design knowledge and rules, accounting for various influencing factors to design gating system elements and generate their computer-aided design models in an efficient manner. To demonstrate the capabilities of the developed system, the results for an industrial case study part are presented. We expect that the proposed system would help reduce manufacturing cost and lead time, alongside bridging gaps between design and manufacturing of the die-casting process.

Development of a semi-automated die casting die design system

2002 ◽  
Vol 216 (12) ◽  
pp. 1575-1588 ◽  
Author(s):  
J Y H Fuh ◽  
S H Wu ◽  
K S Lee
Keyword(s):  
Computer Aided Design ◽  
Die Casting ◽  
Die Design ◽  
Design System ◽  
Prototype System ◽  
Market Demand ◽  
Cad Systems ◽  
Cad System ◽  
Die Casting Die ◽  
Computer Aided

The die casting industry has an imperative need for an automated or semi-automated approach for die casting die design. One of the key challenges that die makers face is how to shorten the lead-time to the market and reduce the cost in die design and manufacturing. Most die makers have employed computer aided design (CAD) systems to improve the efficiency and quality of die design. However, conventional CAD systems do not have the functionality specially for the die casting die design, therefore, a specific computer aided system for die casting die design is needed to meet the market demand. This paper describes a prototype system structured by several functional modules as specific add-on applications on a commercial CAD system for die casting die design. These modules include data initialization, cavity layout, gating system design, die-base, parting, standard component design, etc. Focus of the development will be placed on gating, runner and die-base design.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Die-Casting Die Design Based on the Application of CAE Simulation

2012 ◽  
Vol 201-202 ◽  
pp. 541-544
Author(s):  
Zhi Xin Jia ◽  
Ning Bo Hu ◽  
Ji Qiang Li ◽  
Li Jun Liu ◽  
Li Qiong Chen
Keyword(s):  
Die Casting ◽  
High Volume ◽  
Die Design ◽  
Factors Affecting ◽  
Die Casting Die ◽  
Solidification Processes ◽  
Component Manufacturing ◽  
Pressure Die Casting ◽  
Die Service Life ◽  
Cae Simulation

High pressure die casting is a high volume component manufacturing process which is used extensively in many aspects. There are many factors affecting the quality of die-casting die. In this paper, the CAE simulations of filling and solidification processes for die-casting are studied. Numerical analyses are presented for two practical die-casting parts using HZ CAE software. The temperature distributions and filling states in solidification and filling process are presented. Then the deficiencies of the part are predicted. Based on the analyzing results, the structures of the two dies are optimized and longer die service life and high-quality castings are obtained. It is proved that CAE simulation results can offer a helpful reference for die-casting die design.

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