Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation
This manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive wheels. The model was developed in the commercial cas...
| Main Authors: | , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2020-10-01
|
| Series: | Metals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4701/10/11/1418 |
| _version_ | 1827703542874374144 |
|---|---|
| author | Jun Ou Chunying Wei Steve Cockcroft Daan Maijer Lin Zhu Lateng A Changhai Li Zhihua Zhu |
| author_facet | Jun Ou Chunying Wei Steve Cockcroft Daan Maijer Lin Zhu Lateng A Changhai Li Zhihua Zhu |
| author_sort | Jun Ou |
| collection | DOAJ |
| description | This manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive wheels. The model was developed in the commercial casting simulation platform ProCAST for a production die operating under production conditions. Key elements in the development of the model included the definition of the resistance to heat transfer across the die/casting interfaces and die/water-cooling channel interfaces. To examine the robustness of the modeling methodology, the model was applied to simulate production and non-production process conditions for a die cooled by a combination of water and air-cooling (Die-A), and to a second die for a different wheel geometry (Die-B) utilizing only water cooling for production conditions. In each case, the model predictions with respect to in-die and in-wheel temperature evolution were compared to industrially derived thermocouple (TC) data, and were found to be in good agreement. Once tuned to the process conditions for Die-A operating under production conditions, no further tuning of the die/casting interface resistance was applied. Additionally, the model results, in terms of the prediction of pockets of solid encapsulated liquid, were used to compare to x-ray images of wheels. This comparison indicated that the model was able to predict clusters of porosity associated with encapsulated liquid with an equivalent radius of ~27 mm. |
| first_indexed | 2024-03-10T15:20:32Z |
| format | Article |
| id | doaj.art-3752f60c7fa44bd59e57f42647949902 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-10T15:20:32Z |
| publishDate | 2020-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-3752f60c7fa44bd59e57f426479499022023-11-20T18:28:44ZengMDPI AGMetals2075-47012020-10-011011141810.3390/met10111418Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and ValidationJun Ou0Chunying Wei1Steve Cockcroft2Daan Maijer3Lin Zhu4Lateng A5Changhai Li6Zhihua Zhu7The Department of Materials Engineering, The University of British Columbia, 6350 Stores Road, Vancouver, BC V6T 1Z4, CanadaThe Department of Materials Engineering, The University of British Columbia, 6350 Stores Road, Vancouver, BC V6T 1Z4, CanadaThe Department of Materials Engineering, The University of British Columbia, 6350 Stores Road, Vancouver, BC V6T 1Z4, CanadaThe Department of Materials Engineering, The University of British Columbia, 6350 Stores Road, Vancouver, BC V6T 1Z4, CanadaCITIC Dicastal Co., Ltd., No 185, Long Hai Road, Economic and Technological Development Zone, Qinhuangdao 066011, Hebei, ChinaCITIC Dicastal Co., Ltd., No 185, Long Hai Road, Economic and Technological Development Zone, Qinhuangdao 066011, Hebei, ChinaCITIC Dicastal Co., Ltd., No 185, Long Hai Road, Economic and Technological Development Zone, Qinhuangdao 066011, Hebei, ChinaCITIC Dicastal Co., Ltd., No 185, Long Hai Road, Economic and Technological Development Zone, Qinhuangdao 066011, Hebei, ChinaThis manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive wheels. The model was developed in the commercial casting simulation platform ProCAST for a production die operating under production conditions. Key elements in the development of the model included the definition of the resistance to heat transfer across the die/casting interfaces and die/water-cooling channel interfaces. To examine the robustness of the modeling methodology, the model was applied to simulate production and non-production process conditions for a die cooled by a combination of water and air-cooling (Die-A), and to a second die for a different wheel geometry (Die-B) utilizing only water cooling for production conditions. In each case, the model predictions with respect to in-die and in-wheel temperature evolution were compared to industrially derived thermocouple (TC) data, and were found to be in good agreement. Once tuned to the process conditions for Die-A operating under production conditions, no further tuning of the die/casting interface resistance was applied. Additionally, the model results, in terms of the prediction of pockets of solid encapsulated liquid, were used to compare to x-ray images of wheels. This comparison indicated that the model was able to predict clusters of porosity associated with encapsulated liquid with an equivalent radius of ~27 mm.https://www.mdpi.com/2075-4701/10/11/1418castingA356 wheelplant trialProCASTmodel development |
| spellingShingle | Jun Ou Chunying Wei Steve Cockcroft Daan Maijer Lin Zhu Lateng A Changhai Li Zhihua Zhu Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation Metals casting A356 wheel plant trial ProCAST model development |
| title | Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation |
| title_full | Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation |
| title_fullStr | Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation |
| title_full_unstemmed | Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation |
| title_short | Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation |
| title_sort | advanced process simulation of low pressure die cast a356 aluminum automotive wheels part ii modeling methodology and validation |
| topic | casting A356 wheel plant trial ProCAST model development |
| url | https://www.mdpi.com/2075-4701/10/11/1418 |
| work_keys_str_mv | AT junou advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT chunyingwei advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT stevecockcroft advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT daanmaijer advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT linzhu advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT latenga advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT changhaili advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation AT zhihuazhu advancedprocesssimulationoflowpressurediecasta356aluminumautomotivewheelspartiimodelingmethodologyandvalidation |