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Article

Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation

by
Jun Ou
1,*,
Chunying Wei
1,2,
Steve Cockcroft
1,
Daan Maijer
1,
Lin Zhu
2,
Lateng A
2,
Changhai Li
2 and
Zhihua Zhu
2
1
The Department of Materials Engineering, The University of British Columbia, 6350 Stores Road, Vancouver, BC V6T 1Z4, Canada
2
CITIC Dicastal Co., Ltd., No 185, Long Hai Road, Economic and Technological Development Zone, Qinhuangdao 066011, Hebei, China
*
Author to whom correspondence should be addressed.
Metals 2020, 10(11), 1418; https://doi.org/10.3390/met10111418
Submission received: 2 September 2020 / Revised: 22 October 2020 / Accepted: 23 October 2020 / Published: 25 October 2020
(This article belongs to the Special Issue Numerical and Experimental Advances in Innovative Manufacturing Processes)
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Abstract

This manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive wheels. The model was developed in the commercial casting simulation platform ProCAST for a production die operating under production conditions. Key elements in the development of the model included the definition of the resistance to heat transfer across the die/casting interfaces and die/water-cooling channel interfaces. To examine the robustness of the modeling methodology, the model was applied to simulate production and non-production process conditions for a die cooled by a combination of water and air-cooling (Die-A), and to a second die for a different wheel geometry (Die-B) utilizing only water cooling for production conditions. In each case, the model predictions with respect to in-die and in-wheel temperature evolution were compared to industrially derived thermocouple (TC) data, and were found to be in good agreement. Once tuned to the process conditions for Die-A operating under production conditions, no further tuning of the die/casting interface resistance was applied. Additionally, the model results, in terms of the prediction of pockets of solid encapsulated liquid, were used to compare to x-ray images of wheels. This comparison indicated that the model was able to predict clusters of porosity associated with encapsulated liquid with an equivalent radius of ~27 mm.
Keywords: casting; A356 wheel; plant trial; ProCAST; model development casting; A356 wheel; plant trial; ProCAST; model development

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MDPI and ACS Style

Ou, J.; Wei, C.; Cockcroft, S.; Maijer, D.; Zhu, L.; A, L.; Li, C.; Zhu, Z. Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation. Metals 2020, 10, 1418. https://doi.org/10.3390/met10111418

AMA Style

Ou J, Wei C, Cockcroft S, Maijer D, Zhu L, A L, Li C, Zhu Z. Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation. Metals. 2020; 10(11):1418. https://doi.org/10.3390/met10111418

Chicago/Turabian Style

Ou, Jun, Chunying Wei, Steve Cockcroft, Daan Maijer, Lin Zhu, Lateng A, Changhai Li, and Zhihua Zhu. 2020. "Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation" Metals 10, no. 11: 1418. https://doi.org/10.3390/met10111418

APA Style

Ou, J., Wei, C., Cockcroft, S., Maijer, D., Zhu, L., A, L., Li, C., & Zhu, Z. (2020). Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation. Metals, 10(11), 1418. https://doi.org/10.3390/met10111418

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