|Imede, Santa Mary
|Aniku, David and Imede, Santa Mary. (2020). Design and Simulation of HPDC Injection System for a Die Casting Value Chain for a Local Industry. (Unpublished undergraduate dissertation) Makerere University; Kampala, Uganda.
|A research report submitted to the College of Engineering Design and Art in partial fulfillment of the requirement for the award of the degree Bachelor of Mechanical Engineering of Makerere University.
|The design and simulation of a (High Pressure Die Casting) HPDC machine injection system for
the die casting value chain project was mainly aimed at mitigating the entrained air defect during
filling of the molten metal. Other defects such as cold shuts, porosity, solidification shrinkage
and micro porosity were also taken into consideration. The concern was focused on HPDC due to
its cost effectiveness in the long run in terms of making dies and the post casting machining
process. During the project, an engine piston was designed and virtually casted in Altair Inspire
Cast to establish its flow characteristics and the resulting defects from varying injection
pressures and also apply the various ways of mitigating these defects. In the essence to mitigate
the trapped air defect, several methods such a use of overflow wells, proper design of the runner
and part to be casted making sure that areas of abrupt changes in cross – section are taken care
of. In addition, a control strategies and monitoring system was also designed to help ensure that
the metal injection parameters such as pressure, temperature, velocity of plunger were within a
specified range to ensure the cast quality. In addition, the shot used in this case had an insert to
minimize the cost of replacing the entire sleeve but rather the insert only
|HPDC Injection System
|Design and Simulation of HPDC Injection System for a Die Casting Value Chain for a Local Industry.