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Assessment of Fast Shot Transition Point on Filling Patterns and Casting Quality for Pressure Die Castings / Computer Modeling of Shot Sleeves

The fundamental objective of this project is to understand the effect of casting rate, alloy temperature, type and amount of shot sleeve lubricant, shot sleeve design, and shot sleeve materials on thermally induced shot sleeve distortion. Shot sleeve distortion causes the injection cycle to be interrupted because the plunger tip binds and sticks in the sleeve. This causes excessive wear of the sleeve and tip, increased scrap generation because the proper injection velocities can not be achieved, and cycle time interruptions due to the plunger tip sticking in the sleeve upon ejection of the biscuit. This work is a continuation of a project that has been funded by the Metal Casting Industry of the Future over the past two years. During the first two years of the project, a variety of shot sleeves in commercial use were evaluated using two and three dimensional finite element models. Also, a shot sleeve test stand has been constructed to experimentally determine appropriate heat transfer coefficients for the finite element models. Actual sleeve distortions have also been measured using the test stand.
Ohio State University
Steve Udvardy
North American Die Casting Association
241 Holbrook Drive
Wheeling, IL  60090

phone: (847) 279-0001
fax: (847) 279-0002

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