Design and simulation of high pressure die casting (HPDC) injection system for a die casting value chain for a local industry.

Abstract

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.