Casting Layout Design using CAE Simulation with Automotive Part (Oil Pan)

Authors

  • Hong-Kyu Kwon

Abstract

Background/Objectives: One of the main methods for mass production in modern industry era is the die-casting process. The mold-filling process of aluminum die-casting is important and very complex because of the high speed of liquid metal. In fact, it is almost impossible to calculate the exact mold-filling performance using experimental knowledge in parts with complex features.

Methods/Statistical analysis: Casting Layout is a plan of a holistic casting method of how to design a cavity in a mold, how to design a runner, gating, etc. and how molten metal can smoothly fill the mold cavity with the proper over-flower and air-vent for gas extracts to obtain a complete product. In order to solve those casting problems, CAE simulation widely used at the industrial sites is applied in this casting layout study.

Findings: The system that fills the molten metal into the mold cavities is one of the most important factors that affects the quality of the casting and the various problems that occur in the casting processes. The filling analysis of CAE simulation found the gates size, their location, and the runner system design. And also internal porosities caused by air-isolated area were predicted and reduced with modifying the gate and runner system and the overflows configuration.

Improvements/Applications: The layout designs of a casting product had been used by the heuristic know-how based on a trial-and-error process. The solution achieved in this scientific calculation and analysis save a lot of the fabrication cost and time of the die casting mold and also are applied in the die casting mold design and fabrication process.

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Published

2020-03-26

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Section

Articles