Understanding the Relationship Between Pattern Filling and Part Quality in Die Casting
The objective of this project is to understand the phenomena involved in the filling of the die cavity and the relationships between fill parameters and part quality. The affects of gate geometry at part entry, gate velocity, and slow-to-fast shot acceleration on filling patterns in die casting, and ultimately part quality, will be explored. The results should produce a better understanding of the die filling phenomena under a variety of gate entry geometries, selected common cavity geometries, and gate velocities.
The speed of fill in the die casting process and the fact that the die cavity is encased in a large envelope of steel presents some severe challenges for observing and measuring die fill. The use of physical analog (water, ferrometal) modeling with high speed video photography will be the primary technique used to observe fill patterns. The technique is limited however and must be supplemented with additional measurements and trials. Researchers will attempt to use real-time x-ray with high speed video on a limited number of trials with zinc and an aluminum die. Additional measurement trials will be explored.