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Design of a die-casting die is a critical activity for its manufacturing and further downstream activities. Further, in design of a die-casting die, activities like cavity design, cavity layout and design of gating system are essential components. Design of gating system for a die-casting die is dependent upon a number of parameters which are influenced by part design and die-casting alloy. Gating system design takes much time of the die-casting expert since it requires lot of manual input and a number of iterations to finalize the design. This requires a good knowledge of die-casting process, making this activity completely dependent on the user. In modern day industry lot of CAD/CAM tools are being applied for design, development and manufacturing of a die-casting die. However, dependency on a die-casting expert throughout design and manufacturing of die-casting die makes it a quite lengthy process. Gating system design being one of the major activities in die design also takes much time. Therefore, it would be quite beneficial to automate the activity of the gating system design. This work is about computer aided design of gating system for die-casting die. Proposed system takes CAD file of the die-casting part as input and uses die-casting process knowledge to determine different parameters for the gating system. Designs of the components of the gating system like runner, gate and overflow have been attempted. A feature library has been proposed as a part of this work which together with parametric design of the gating system generates CAD model of the components of the gating system. The system has been tested on a number of industrial parts and results found are quite encouraging. The system would go a long way in bridging the gap between designing and manufacturing of die-casting.
Directional Solidification of Steel Castings summarizes the results of a large number of investigations, mostly scientific in character, on the directional solidification of steel castings. The influence of design on the technical possibilities of producing casting in the foundry is examined. Diagrams, simple basic rules, and formulae are provided, along with many practical examples. This book is comprised of 16 chapters and begins with an introduction to the technical and psychological aspects of steel casting before turning to a discussion of the influence of shape and dimensions on the time it takes for castings to solidify. The thermal gradient, feeder heads, and cavities in steel castings are then considered. In particular, the effect of the thermal gradient on solidification and feeding range are examined. Methods for increasing the thermal gradient in the casting are described, including the use of mold heating pads, breaker cores or Washburn cores; external cooling (iron chills); cooling fins; internal chills; and exothermic pads. Cavities in steel castings which are commonly mistaken for true shrinkage cavities are also analyzed. This monograph is particularly suitable for foundry managers, foremen, technicians, casting designers, and students.
This book helps foundrymen eliminate or minimize inherent casting problems, imrpove casting quality and reduce cleaning and finishing costs.
Designing in sand casting is a critical activity for manufacturing. Further, activities like cavity design, cavity layout and design of gating system are essential in design. Design of gating system in sand casting is dependent upon a various parameters. Gating system design requires lot of manual input and a number of iterations to finalize the design. This requires a good knowledge of casting process, making this activity completely dependent on the user. In present day industry, lot of CAD/CAM tools are applied for design, development and manufacturing. However, need of sand casting expert throughout design and manufacturing makes it a quite lengthy process. Gating system design being one of the major activities also takes much time. Therefore, it would be quite beneficial to develop a system for automated generation of gating system. Proposed system takes CAD file of the die casting part as input and uses sand casting process, machine and alloy knowledge to determine different parameters for the gating system. Designs of the components of the gating system like runner, gate and overflow have been attempted. A feature library has been proposed as a part of this work which together with parametric design of the gating system generates CAD model of the components of the gating system. The system would go a long way in bridging the gap between designing and manufacturing of die-casting.
Master's Thesis from the year 2017 in the subject Engineering - Mechanical Engineering, grade: 8, , language: English, abstract: This work presents a system that would help in automatic design of multi-gates for multi-cavities dies. The system is able to automate: (i) the determination of the placement of gate, and (ii) determination of the shape of gate for die-casting parts having simple shapes. The system has to be implemented in GUI of MATLAB 7.10 using the best industry practices and recommendations from NADCA for gating-system design. The proposed system is able to generate parameters of multi-cavity gating-system for parts requiring multi-gates from the part model data. The other information required for working of the system includes material properties, die-casting process parameters and die-casting casting machine parameters which comes under the data initialization process. The parameters of the gating-system which are determined by the system are used for design of gating-system for the multi-cavity dies. This is done by updating the parameters of pre-modeled gating-system features stored as feature library. Chapter 3 , 4 and 5 present the various modules of the system along with its implementation on case-study parts. The results from the case-studies are quite encouraging and are in-line with the best industry practices. The present work describes a novel methodology for computer-aided automatic placement of the gating system for a die-casting part. it uses the parting line information to identify the probable positions for the placement of the gating system. This aspect of die-design has not received due attention of the researchers in the past. Moreover, the automated gating-system design for die-casting parts that require multiple agates in a multi-cavity die has not been attempted. Both these features provide the originality to the present work.
This book, Casting Processes and Modelling of Metallic Materials, explores the various casting and modelling activities related to metallic alloy systems. The book provides results of research work conducted by experts from all over the globe to add to the research community in the era of the casting process and modelling. The book was edited by two experts in the field of materials science and modelling, Dr. Abdallah and Dr. Aldoumani, whom both have several publications in peer-reviewed journals, worldwide conferences, and scientific books. The book introduces the casting processes and then discusses the various issues and possible solutions. Over the past years, various models have been proposed and utilized to predict the performance of castings. Some of these models proved to be accurate whereas others failed to predict the casting performance. The strength of any predictive tool depends on the employment of physically meaningful parameters that replicate the real-life conditions. This has been illustrated in the current book with such predictive models and finite element (FE) modelling to illustrate the behaviour of castings in real-life conditions.