Design and optimisation of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation
Design and optimisation of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation
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DOI：
10.1016/s0924-0136(00)00546-x
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发表时间：
2000-09-07
影响因子：
6.3
通讯作者：
Pinwill, I
中科院分区：
文献类型：
--
作者：
Hu, BH;Tong, KK;Pinwill, I
一个设计良好的流道和浇注系统是非常重要的，以确保高质量的压铸件，通过提供一个均匀的模具填充模式。数值模拟是设计浇道和浇注系统的一种经济有效的工具，可以直观地分析充型过程。选择一种薄壁镁合金通讯件进行热室压铸，并应用数值模拟技术对流道和浇注工艺进行了优化。设计并分析了两种类型的流道和浇注系统。采用分体式浇注系统的初步设计导致了旋涡填充模式和中心流动不足，导致边缘过早关闭，使最后填充的区域落入零件的内部部分。这导致了高可能性的空气夹持在铸件和设计是不适当的部分。通过采用连续浇注系统和更大尺寸的流道对设计进行了改进。浇口面积增大，浇口速度略有降低。数值模拟结果表明，新设计提供了均匀的充型模式，最后充型区域位于零件的上边缘，在此位置可以方便地连接溢流和通风口。在研究中，制造了两种设计的模具镶件。进行了一系列铸造试验。短粒充填试验表明，模拟结果与实际铸造结果吻合较好。利用优化后的流道和浇注系统，生产出了微结构良好的薄壁电信件。(C) 2000 Elsevier Science S.A.版权所有
A well-designed runner and gating system is very important to secure good quality die castings through providing a homogenous mould filling pattern. Numerical simulation is a cost-effective tool in the design of runner and gating systems to visibly analyse the mould filling process. A thin-walled magnesium telecommunication part was selected to be hot chamber die cast and a numerical simulation technique was applied for the optimisation of the runner and gating. Two types of runner and gating systems were designed and analysed. A preliminary design with a split gating system led to a swirling filling pattern and insufficient central flow, which prematurely closed the edges and left the last filled areas falling into the inner portion of the part. It resulted in a high possibility of air entrapment in the casting and the design was not proper for the part. The design was improved by using a continuous gating system and a bigger size runner. The gate area was increased and the gating speed was slightly reduced. Numerical simulation showed that the new design provided a homogenous mould filling pattern with the last filled areas being located at the upper edge of the part, where overflows and vents were conveniently attached. For the study, die inserts for both designs were fabricated. A series of casting experiments were conducted. The short shot filling tests proved that the simulation results matched the actual casting results very well. Good quality thin-walled telecommunication parts with sound microstructure were produced based on this optimised runner and gating system. (C) 2000 Elsevier Science S.A. All rights reserved.