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Autonomous Optimization of Uncertainties inside the High Pressure Die Casting Process

March 1, 2017

The High Pressure Die Casting Method

In theory, the high-pressure die casting course of action is uncomplicated: Molten metal is injected in to the mould, solidifies a few seconds later and is then ejected as a casting. The mould gets treated having a lubricant to prevent possessing the casting stick to the mould then closed for the subsequent "shot".

In reality, this simple-sounding procedure is very unstable. As an example, a nozzle intended to spray lubricant on the mould surface could loosen and spray more than a wider region than intended - or could clog partially or totally, restricting the amount and area on the spray. Missing a sufficient layer of lubrication, castings may possibly stick within the mould, crack through ejection then have to be discovered inside the production batch and scrapped.Similarly, melt volume in the holding furnace in the die-casting machine can change the melt volume dosing in to the machine chamber. This in turn changes the metal fill pattern into the cavity by escalating turbulences and the amounts of air which might be entrapped in the casting creating porosities. Or think about a standard variable: the temperature on the mould. So as to eradicate pre-solidification during cavity filling the mould must be brought to operating temperature of approximately 400° F / 200°C.

However, the liquid melt injected into the mould heats it beyond this temperature, which, if left unaddressed, would influence the functional life with the mould. In an try to regulate this variable, liquid cooling medium containing flowing water or oil is forced via channels in the die steel. Even so, the mould itself modifications more than the course of a production run; as it heats from area to production temperature, it increases in size; elements that held the mould closed in an unheated state may well no longer function properly or completely. Even the situation with the die-casting machine itself changes during a production week; adjustments produced on a cold machine yield distinctive scale readings when the machine reaches production temperatures. Variations are present when unexpected breaks take place; the longer the machine stops, the much more tricky it becomes for the operator to equilibrate the temperatures again. In addition, mould aging affects casting final results: the mould wears at diverse speeds in different locations, affected by melt flow patterns, location of clamps, scale build-up in cooling lines - all of which demand the operator to continually strive to equilibrate the mould temperature.

In quick, the high-pressure die casting process is in continuous flux - along with the outcome is in the hands on the shop floor private.

Process Simulation

Blaming only the shop floor personnel for negative castings will be as straightforward since it is unfair. Within the most circumstances, poor quality benefits not in the efforts in the floor personnel, but from far earlier inside the engineering process: the production procedure may have been insufficiently created; the casting shape might have been poor made. In either case, a good excellent casting will never ever be achieved. This really is where procedure simulation is often of the greatest enable.

Inside the initially stage of approach organizing, casting simulations can be performed, long before cutting die steel or the release of the final casting design. Employing CAD files on the early casting design suggestions in mixture with theoretical process parameters, simulations directly point to potential issues. At this point of improvement, the casting style and manufacturing process may be changed conveniently, swiftly and inexpensively. With expertise, a well-trained die casting engineer making use of simulation tools can make a method that yields great top quality castings during the initial die trials.

Within the most circumstances this results is achieved by designing a mould applying one particular set of achievable approach parameters only. Given the volume of parameters feasible inside the casting approach, and the array of variation within those parameters, the amount of potential interactions that the engineer could contemplate approach infinity - as would the time required to study those possibilities.With limited time and resources - and possessing achieved these fantastic castings through single parameter simulation - the engineer may perhaps quit at this point, and turn his consideration to a further project, leaving shop floor personnel to resolve any additional production variations.

Autonomous Optimization and Uncertainties

Autonomous optimization is mainly employed to seek out a good procedure set but also can quickly recognize dependencies and sensitivities amongst these method parameters; which include casting and cavity designs, fill and cycle occasions, mould and melt temperatures, and their levels of variations can be defined within the plan and simulated. The optimization software program autonomously selects parameter, simulates the set and evaluates the results. By smart choice determined by genetic algorithms one of the most effective parameter set will probably be found out on the thousands doable variations.

Autonomous optimization should not simulate all possibilities and define the 'best"; rather, the target would be to find an optimum inside the shortest time and also the least amounts of simulations - and without requiring more than two hours of your engineer's time (one hour for setup, one particular hour for outcome evaluation.) As the simulations are carried out on an office personal computer and don't influence production, the engineer can simultaneously continue to perform on other projects.

Moreover, as parameter sets are not lost after the simulation has been completed, they can also be additional analyzed at a later time and in higher detail of sensitivities to each other. To start an optimization, parameter values are selected by random or determined by designs of experiments. Carrying out so should really present sufficient results to calculate sensitivities among the defined parameter even before beginning the optimization. Sensitivity analyses are a by-product from the autonomous optimization; making use of a smaller design and style of experiments, this beginning array might be increased and analyzed by its own.

Creating very good castings inside a stable course of action is definitely an achievable purpose; it should not, nonetheless, preclude developing further improvements. Admittedly, it is actually pretty hard to look for uncertainties beneath production circumstances, let alone to acquire consent from management to cease production to be able to look for uncertainties, which may not exist at all. But what is virtually not possible to achieve around the shop floor could be a simple target for simulation tools. As an example, controlling a single variable, like mould temperature, could possibly be feasible, if challenging, around the shop floor - but experimenting with adjustments for the mould via welding and grinding may be impractical inside a functioning circumstance. Time and personnel could be required for each and every alteration, and also the cumulative impact from the welding and grinding would reduce die life for the extent that this experiment would not make much sense. Making use of a laptop or computer simulation on the adjustments, nevertheless, enables the engineer to analyze the efficacy without having threatening the life in the die. As opposed to truly welding the mould, a CAD file is replaced autonomous plus the selection of a temperature profile is carried out together with the push of a button.

The usage of simulation application can also be more effective than 'real world' experiments; in lieu of shutting down a production line for 'trial and error' experiments, one particular set of parameters is often analyzed by way of a simulation even as the production of other casting continues, resulting in much more effective production of higher high quality castings. Even so, the engineer should really take into account the time frame involved together with laptop or computer hardware availability, and pick the most significant variables. Look at the task facing an engineer who wants to optimize a casting method by taking into consideration the following variables: mould temperature ranging from 250° F and 450° F in 50° F increments provides five levels of variation; three levels for the use of a lubrication nozzle; 4 levels for pouring temperature; 3 for pouring volumes and two for diverse casting designs final results in 360 iterations to simulate. Based around the casting design and use of a normal desktop computer system one particular simulation could take up to one particular hour; to method all 360 permutations could take 15 days - nevertheless far quicker than attempting to perform so on a production machine, giving that such an examination is attainable at all. Making use of a lot more effective computer system this benefit leans much more towards simulations. Not to stretch the releases of more rapidly machines inside the future. Even nowadays by investing in high-end gear the discussed calculations may be carried out in less than three days.


Using state with the art laptop or computer hardware and also the suitable simulation system, engineers can supply far more details about their High Pressure Die Castings process even ahead of process improvement than through production ignoring simulation at all.Ahead of implementing fabrication, processes may be optimized, influencing parameter could be identified, dependencies might be defined and tolerances can be implemented depending on these dependencies and variations in influencing parameter. With this know-how at hand and also the right monitoring systems, production processes are well understood and in a position to create excellent castings beneath stable circumstances.


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