Design and Thermal Analysis Simulation of Gravity Die Casting on Aluminium Alloy (ADC12)
In the mold design scope, the quality of the casting product is important to fulfill customer satisfaction. Effective casting of pressure-tight casting need close conformance to the principle of sound casting product design. Guidelines concerning corners, ribs, fillets and chamfer should be follow carefully to avoid casting defect on the product. In this project, describes about to optimize design and simulation of vertical and horizontal position of cavity design by using ANYCASTING and FLEXPRO software thermal analysis at the certain area of the mold cavity. The result shows, vertical mold design produced less defects than the horizontal mold design and filling time for vertical mold design is 1.6546 seconds and complete solidification time is 504.7066 seconds. For the partial tracing analysis, it shows double turbulence occurs on the horizontal cavity and single turbulence on horizontal cavity.
M. Khan, M. Aljarrah, J. Wood, and M. Medraj, “The effect of cooling rate on thermophysical properties of magnesium alloys,” Journal of Materials Research, vol. 26, no. 8, pp. 974–982, 2011.
E.H. Smith. Mechanical Engineer's Reference Book, 12th Edition. Oxford: Butterworth-Heinemann, 1994.
M. Sasikumar, “Design and Thermo-structural Analysis of Disc Brake,” International Journal in Physical & Applied Sciences, vol. 1, no. 3, pp. 11-16, 2014.
E. Stuart, Booth and D.F. Allsop, “Thermal control and design of die-casting dies,” Diecasting Metal Molding, vol. 10, no. 6, pp. 7–8, 28, 1981.
H.M. Roshan, V.M.K. Sastri and R. Agarual, “Die temperature control in pressure die-castings,” American Foundry Society-Transaction, vol. 105, pp. 493–495, 1991.
P.E.J Linton, “Using thermographic analysis to reduce defects and extend die life,” Die Casting Engineer, vol. 38, no.4, pp.26–32, 1994.
W.R. Schmidt, R.D. White, C.E. Bird and J.V. Bak, “Conformal Cooling Versus Conventional Cooling: An Injection Molding Case Study With P-20 and 3DP™-Processed Tooling,” MRS Proceedings, vol. 625, 2000.
D. Emadi, L.V. Whiting, S. Nafisi and R. Ghomashchi, “Applications of thermal analysis in quality control of solidification processes,” Journal of Thermal Analysis and Calorimetry, vol. 81, no. 1, pp. 235–242, 2005.
F.R. Hernández and J. Sokolowski, “Thermal analysis and microscopical characterization of Al–Si hypereutectic alloys,” Journal of Alloys and Compounds, vol. 419, no. 1-2, pp. 180–190, 2006.
A. Canales, J. Talamantes-Silva, D. Gloria, S. Valtierra, and R. Colás, “Thermal analysis during solidification of cast Al–Si alloys,” Thermochimica Acta, vol. 510, no. 1-2, pp. 82–87, 2010.
L. Bäckerud, G. Chai, and J. Tamminen, “Solidification characteristics of aluminium alloys - Foundry Alloys,” American Foundry Society-Transaction, vol. 2, 1990.
S. G. Shabestari and M. Malekan, “Assessment of the effect of grain refinement on the solidification characteristics of 319 aluminum alloy using thermal analysis,” Journal of Alloys and Compounds, vol. 492, no. 1–2, pp. 134–142, 2010.
S. G. Shabestari and S. Ghodrat, “Assessment of modification and formation of intermetallic compounds in aluminum alloy using thermal analysis,” Materials Science and Engineering: A, vol. 467, no. 1–2, pp. 150–158, 2007.
S.M. Liang, R.S. Chen, J.J. Blandin, M. Suery, and E.H. Han, “Thermal analysis and solidification pathways of Mg-Al-Ca system alloys,” Materials Science and Engineering: A, vol. 480, no. 1–2, pp. 365–372, 2008.
M. Malekan and S. Shabestari, "Effect of Grain Refinement on the Dendrite Coherency Point during Solidification of the A319 Aluminum Alloy," Metallurgical and Materials Transactions A, vol. 40, no. 13, pp. 3196-3203, 2009.
M. Malekan and S. Shabestari, "Computer-aided cooling curve thermal analysis used to predict the quality of aluminum alloys,” Journal of Thermal Analysis and Calorimetry, vol. 103, no. 2, pp. 453-458, 2010.
M. Mahfoud, A. Prasada Rao and D. Emadi, "The role of thermal analysis in detecting impurity levels during aluminum recycling," Journal of Thermal Analysis and Calorimetry, vol. 100, no. 3, pp. 847-851, 2010.
S. Farahany, A. Ourdjini and M. Idris, "The usage of computer-aided cooling curve thermal analysis to optimise eutectic refiner and modifier in Al–Si alloys," Journal of Thermal Analysis and Calorimetry, vol. 109, no. 1, pp. 105-111, 2011.
S. Farahany, A. Ourdjini, M. Idrsi and S. Shabestari, "Evaluation of the effect of Bi, Sb, Sr and cooling condition on eutectic phases in an Al–Si–Cu alloy (ADC12) by in situ thermal analysis," Thermochimica Acta, vol. 559, pp. 59-68, 2013.
I.D. Gloria, “Control of grain reﬁnement of AI–Si alloys by thermal analysis,” Ph.D. thesis, Department of Mining and Metallurgical Engineering, McGill University, Montreal, Canada, 1999.
M. B. Djurdjevic, I. Vicario, and G. Huber, “Review of thermal analysis applications in aluminium casting plants,” Revista de Metalurgia, vol. 50, no. 1, pp. 1–12, 2014.
P. Huang and C. Lin, "Computer-aided modeling and experimental verification of optimal gating system design for investment casting of precision rotor," The International Journal of Advanced Manufacturing Technology, vol. 79, no. 5-8, pp. 997-1006, 2015.
E. Niyama, T. Uchida, M. Morikawa and S. Saito, “A method of shrinkage prediction and its application to steel casting practice,” American Foundry Society - International Cast Metals Journal, vol. 7, pp. 52–63, 1982.
K. Carlson, S. Qu and C. Beckermann, "Feeding of high-nickel alloy castings," Metallurgical and Materials Transactions B, vol. 36, no. 6, pp. 843-856, 2005.
Authors who publish with this journal agree to the following terms:
- Authors transfer copyright to the publisher as part of a journal publishing agreement with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after the manuscript is accepted, as it can lead to productive exchanges, as well as earlier and greater citation of published work (See The Effect of Open Access).