Manufacturability analysis of die cast components through parametric analysis

Abstract

Die casting continues to be an attractive and feasible process to produce high newlinevolume items in mass, bythe metal working industry. The process is eminently suitable to newlineproduce items for consumer, commercial and industrial applications. Die cast parts can be as newlinesimple as a sink faucet or as complex as a connector housing newlineThe final quality of a die cast product is primarily dependent on the material, die and newlinethe geometry of the product related to Feature, shape, position, orientation, size and number. newlineKeeping the parameters such as material and the Die as invariant, the quality of the finished newlineproduct invariably is dependent on the geometry. newlineDie casting process is quite complex process with focused attention to be bestowed on newlinemany variants of the process such as pressure, temperature and time setting. It involves an newlineanalysis of combined heat and fluid flow characteristics since the heat input is cyclic and the newlineheat dissipation along with forced heat removal is continuous, which in turn results in newlinemaintaining thermal equilibrium of the die. Therefore these parameters have to be optimized newlinein order to achieve the quality of the castings besides process productivity. A complex newlinesituation related to the process such as this, necessarily requires the knowledge of an newlineexperienced tooling professional well trained with the selection of the processing parameters, newlinewhich in turn is largely dependent on the geometry of the product. It is also a fact that newlinedesigners of die casting product invariably follow trial and error techniques that too newlinedepending on specific Thumb Rules to realize providential final products as per the newlinerequirements newlineIt is in a scenario such as this, the present work aims at capturing the nondeterministic knowledge related to the process as is available with an expert in the field and newlinecoupling it with the deterministic knowledge available in the form of empirical relations,etc newline