Investigation on Temperature Profile of Casting die in pressure die casting process

Abstract

Thermal profile of die for pressure die casting play an important role to manufacturing casting automobile parts. In this process, molten metal is poured and newlineapplied pressure on it to fix in die. Within 20 second of time liquid metal is converted into usable product form. This was only successfully possible after various numbers of newlineattempt made on pressure die casting machines. For new product it is quite difficult to forecast thermal profile for die as well as casting parts. Quality of casting parts newlinestrongly depends on temperature distribution of die. This distribution can be controlled by water mass flow rate applied to die for cooling purpose. This cooling newlineprofile neither too sudden nor too gradual. Optimum temperature distribution required in die and casting part contact area. It is necessary to study the process newlineparameters on the performance of the die because the commercial setup is uneconomical. newlineHence, an attempt is made to investigate the effect of parameters on the thermal performance (cooling time) of the die. Analytical, FEM and semi empirical newlinemodel developed for die analysis in pressure die casting process. Furthermore, die test rig also developed for experimental work, to conduct experimental investigation on newlinedie considering factor, as mass flow rate of water to die cooling time was considered. newlineAnalytical model is used to predict cooling time for specific die geometry and material of die. Semi empirical model can be effectively used for estimating the newlinecooling time of pressure die casting mold. The method is very simple and easy to implement. Thus, expensive experimental runs related to pressure die casting can be newlineeliminated. CFD tool is also capable to measure a temperature variation with respect to time at any point and portion of die geometry, this is found very difficult in actual newlinePDC machine. Based on experimentation work it was proven that developed test rig is capable to provide temperature profile of die materials which are used in pressure die newlinecasting industries.