Study on Effect of Die Temperature on the Quality of the Products in HPDC Process with the help of Flow Simulation

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072
© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1479
Study on Effect of Die Temperature on the Quality of the Products in
HPDC Process with the help of Flow Simulation.
Shivkumar biradar1, Prashant Borlepwar2
1M.tech student Dept. of Mechanical Engineering, MIT, Aurangabad(MH), INDIA
2Professor, Dept. of Mechanical Engineering, MIT, Aurangabad(MH), INDIA
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Abstract - Die temperature in high-pressure die casting of
A380 alloy is optimized by experimental observation and
numerical simulation. Ladder frame (one part of the new
motor EF7) with a very complicated geometry was chosen as
an experimental sample. Die temperature and melt
temperature were examined to produce a sound part. Die
temperatures at the initial step and the final filling positions
were measured and the difference between these values was
calculated. ProCAST software was used to simulate the fluid
flow and solidification step of the part, and the results were
verified by experimental measurements. It is shown that the
proper die temperature for this alloy is above 200°C.
Key Words: Die temperature, high-pressure die casting,
solidification.
1.INTRODUCTION
High-pressure die-casting (HPDC) process has been widely
used to manufacture a large variety of products with high
dimensional accuracy and productivities.Ithasamuchfaster
production rate in comparison to other methodsand it is an
economical and efficient method for producing components
with low surface roughnessand high-dimensional accuracy.
All major aluminum automotive components can be
processed with this technology [1–7]. In this process, the
metal is injected into the die at high speeds(30–100 m/sand
typically 40–60 m/s for aluminum alloys[2])andunderhigh
pressure through complex gate and runner systems [3].
Although HPDC has a considerably higher speed than other
metal forming processes, due to complexity of the process
and the number of variables, optimization of the process is
essential. In particular, there are issues related to control of
die temperature, solidification of the components, quality
control of the castings, and more important, developmentor
use of a coherent and integrated system. The mechanical
properties of a die-cast product are principally relatedtothe
die temperature, the metal velocity at the gate, and the
applied casting pressure [4].
Combination of die temperature, fluidityofthemoltenmetal,
geometrical complexity of the parts, and cooling rate during
die casting affect the integrity of a cast component. If these
parameters are not adequately controlled, various defects
within the finished component will be expected [6, 7].
Thermal profile of the die during operation is another
important factor in the production of high-quality
components. Too high temperature of the die will lead to
longer solidification which consequently prolongs the cycle
time, while a cold die will contribute to a number of surface
defects [3, 8, 9].
Kermanpur et al. [10] used FLOW-3D software to simulate
the filling and solidification sequences of two automotive
components. They process the appropriateness of the
running and feeding systems. Schneiderbauer et al. [11]
investigated the flow of molten metal in the die cavity
threefoldly: (a) analytically, (b) experimentally, and (c)
numerically. They studied the effect of flow condition on
casting defects. Pereira et al. [12] used ProCAST software to
simulate HPDC process. They studied the effect of the die
temperature and melt temperature die life. Rai et al. [13]
worked on optimization of main process parameters in
HPDC, namely, die temperature, melt temperature, and
plunger velocity. Some other investigatorshavealsoworked
on optimization of process parameters on die-casting by
simulation [14–16]. However in many of these works, the
geometry of the part is simple and there are few researches
on very complex part in industry. The aim of this work is
optimization of process parameters in die casting of a
complex automotive component named ladder frame by
simulation.
1.1 Governing Equations
In order to perform the mould filling and solidification
simulation of automotivepart, the commercialfiniteelement
code ProCAST was used. Within the framework of an
Euclidian description, this software is capable of solving
simultaneously three-dimensional transient thermal and
fluid flow problems with free surface. The set of partial
differential equations to be solved is briefly summarized
below.
Mass Balance
where ρ(N/m2)and ν(m/s)are the volumetric mass and the
velocity of the fluid, respectively.
Momentum Balance
where g(m/s2) is the gravitation vector, p(N/m2)isthefluid
pressure, and σv is the viscous stress tensor.

Energy Balance, Written as an Enthalpy Formulation
1.2 Modeling Procedure
A 3-dimensional model of the cast product is an important
input for design and analysis functions in ProCAST and can
be imported through a data exchange interface using the
industry standard Parasolid format (Figure 1). The material
properties of the alloy were extracted from the software
database and are shown in Table 1.
Table 1: Material properties.
Figure 1: Geometry of ladder frame product.
In order to evaluate the effect of process parameters on the
filling pattern and quality of the final product, three main
process parameters were varied during simulationandtheir
effects on the results were studied. Initial and boundary
conditions used in the simulation are given in Table 2. To
ensure mesh independency of the results,twodeferentmesh
sizes were used and simulation results were compared at
these two mesh sizes.
Table 2: Initial and boundary conditions.
2. Experimental Procedures
The material used in this study was A380 material. Die
temperatures were 150°C, 200°C, and 250°C. Initial melt
temperature of 680°C, shot sleeve speed of 3 m/s, and speed
melt in gate of 55 m/s for the ladder frame were assumed.
Measurement of the melt temperature was carried out by
thermocouple and Laser pyrometer (model chy 110) at the
die surface.
Melt temperature was measured at the die entrance at the
start of injection and at the end of filling. This test was done
at the various die temperatures. The IDRA1600 die-cast
machine wasused for injection. Test resultsareillustratedin
Table 3 and Figures 2–4.
Table 3: Melt temperature at outset injection in shot
sleeve and at end injection final filling position.
Figure 2: Melt temperatures at die entrance and start
injection versus die temperatures.
Figure 3: Melt temperatures at the end of the die and end
injection versus die temperatures.

Figure 4: Reduction of melt temperature at various die
temperatures at the initial and the end of injection.
The variations of melt temperature versus die temperature
in different cases are shown in Figure 2. The results show
that the die temperature variesfrom 150 to 250°C, whilethe
melt temperature varies between 660°C and 680°C.
Figure 5 shows typical examplesof cold flow surface defects
in pieces produced in a die with temperature of 150°C
(Figures 1–3). As can be seen from this figure, cold shot
defects occur at final filling positions predicted by the
software.
Figure 5: Cold flow surface defects at final filling
positions.
This kind of defect occurs because the melt has to move a
long way in the die cavity and finally it reaches its liquidus
temperature. If the metal is partially solidified when two
flowscome together, the lapsare formed and laminations,as
the characteristic of surface defects, appear. This defect is
often apparent at the end of the flow patternespeciallywhen
the die is colder. Overflowswere added in these positions to
eliminate these kinds of defects (Figure 6).
Figure 6: positions of added overflows to the mold.
Gas porosities caused by entrapped air during metal
injection are illustrated in Figure 7. Porosity caused by
turbulent flow, low die temperature, and long flow path in
combination with a thin wall section. An example of
turbulent flow pattern of the melt at three holes in front of
the gate is shown in Figure 8(a). These holes cause agitation
in the flow pattern. This agitation can result in air
entrapment and oxidation and also they can change the flow
pattern of the molten metal to a more turbulent one and
cause branch-like flow. By eliminating these three holes in
the model (Figure 8(b)), more stable flow pattern was
observed. Some other possible sites of air entrapment are
shown in Figure 9(d). These sites have been generated as a
result of complex and branch-like flow pattern in the mold.
(a)
(b)
Figure 7: Some porosity defects.

(a)
(b)
Figure 8: Velocity vectors of the melt at the three holes in
the front of the gate.
(a)
(b)
(c)
(d)
(e)
(f)

(g)
Figure 9: Steps filled die by the melt and show End points.
Simulations Results
The boundary conditions implemented in the software are
shown in Table 2. Then, the model was run for die
temperatures of 150°C, 200°C, and 250°C while other
parameters kept constant. The flow pattern ofthemeltinthe
die at 200°C is shown in Figure 9.
Temperature distribution of the melt in two different die
temperatures at equal time is compared in Figure 10. In the
case of 150°C die temperature, melt temperature falls down
near the liquidus temperature of the material and there is
danger of cold shot flow in this case.
(a1)
(a2)
(a3)
(b1)
(b2)
(b3)
Figure 10: Flow pattern of melt with die temperature (a)
150°C and (b) 250°C in same time a1=b1. Time a2=b2 and
a3=b3.

Figure 11 shows the final solidification positions at the end
of casting. Shrinkage defects occurred at the final
solidification positions are shown in Figure 12. Inthisfigure,
one can see a comparison between simulation results and
experimental observation at those areas. The outer side of
the part has shrinkage defects which were predicted by the
software. The verified model interestingly represented the
correct location of the porosity defects in the castings.
Figure 11: Hot spots at the end of solidification step,
which are susceptible to casting defects.
Figure 12: Defects occurred in final solidification
positions.
3. DISCUSSION
The difference of two melt temperature curves at the initial
and end of the process at 250°C, 200°C, and 150°C are 9.5°C,
10°C, and 19.5°C, respectively (Figure 3). It isseenthatthere
is a break point in the curve of end injection at die
temperature of 200°C. Therefore, defects are more probable
at die temperatures less than 200°C. These results are
supported by experimental observations. With regardtothis
break point, it can be seen that the normal die temperature
for this alloy is 200°C. Maximum temperature depends on
the die cooling system and optimized cycle time for
production of a specific part.
Filling pattern of the melt is shown in Figure 6. Final filling
positions in the die are illustrated in this figure. Same thing
wasobserved at the die temperature of 150°C (Figures1–3).
Filled Percentagesof mold at two die temperaturesof 150°C
and 250°C are shown in Figure 5. By comparing result at
equal time steps, filled percentage of die at the die
temperature of 250°C is more than that of 150°C.
Figures 11 and 12 show the results of solidification
simulation. In this figure, it is seen that the peripheralareaof
the part is at the liquid phase while other areasaresolidified.
Therefore, these areas are susceptible to formation of
shrinkage porosities. In order to reduce the coldflowdefects
and air porosities, overflows can be placed near these areas
in the die design
4. CONCLUSIONS
1) Comparison of the experimental and simulation results
indicates that defects in the pieces are placed at the
predicted places by simulation.
2) Optimum die temperature for A380 alloy for H13 die
material is around 200°C.
3) If the die temperature is reduced from the optimum
temperature range, probability of cold flow defects and air
porosities increase.
4) Determination of optimized places of overflows by
simulation led to decrease of some casting defects such as
cold shots and air porosities.
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BIOGRAPHIES
M.Tech Student, Maharashtra institute
of technology, Aurangabad
Area of Interest-Aluminum Die casting
process optimization.
Assistant Professor, Maharashtra
Institute of Technology, Aurangbad
Area of Interest-EDM and WEDM
process optimization.

Study on Effect of Die Temperature on the Quality of the Products in HPDC Process with the help of Flow Simulation

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