PROCESS OPTIMIZATION OF PRESSURE DIE CASTING TO ELIMINATE DEFECT USING CAE SOFTWARE

Vinod V Rampur

Abstract: Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner and overflow location and optimize the gating system and process parameters for best quality product and improved productivity. Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the casting. Mould filling and solidification process of a part was simulated using Z-cast software

Keywords: Casting, HPDC, Z-cast, CAE Software, Simulation.

DOI: https://doi.org/10.15623/ijret.2016.0501031