Developing a clamping system for die casting machine in a die casting value chain for a local industry

Abstract

In this project, the toggle clamping unit for die casting machine is modeled using Solidworks18. While using Solidworks simulation analysis tools, the finite element analysis (FEA) of the unit is carried out to predict its real-world behavior. The clamping unit deformation, fatigue analysis and stress results are obtained basing on the topology optimization as the recommendations for an improved structure. For fatigue analysis of 1600T, the life of the structure is checked for design life. The finite element analysis results are checked and are compared with acceptance limits of stress and design life. The results show that the max von misses stress is smaller than the allowable design stress for the material. The maximum stress obtained was 4.585e8 N/m2 which is less than allowable stress of ductile iron 5.515e8 N/m2. According to Von Misses stress criterion provided by the system, the components are designed with a factor of safety 2. Maximum deformation was around the injection hole of the movable and stationary platen which was 0.927mm and only 0.001 mm at the holes of the tie bars. It is observed that the force is uniformly distributed thus achieving clamping uniformity, and clamping force repeatability precision.