Design and Process Optimization in Die Casting Through Conformal Cooling

Boopathy Janarthanam; Rushikesh Nanasaheb Patil; Mayur Laxmanrao Jadhav

doi:doi:10.11648/j.ijmea.20221004.12

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Design and Process Optimization in Die Casting Through Conformal Cooling

Boopathy Janarthanam, Rushikesh Nanasaheb Patil, Mayur Laxmanrao Jadhav

Published in International Journal of Mechanical Engineering and Applications (Volume 10, Issue 4)

Received: 9 June 2022 Accepted: 12 July 2022 Published: 17 August 2022

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Abstract

This study aims to implement the conformal cooling in die casting dies to reduce the cycle time and rejections due to shrinkage porosity. In this paper we have done a flow simulation between conventional cooling and conformal cooling to optimize the cooling time/solidification time reduction and shrinkage porosity reduction in die casting parts where the thick mass area/high wall thickness occurs. In die casting process cycle time Solidification time plays a vital role. In order to optimize the die casting process cycle time, conformal cooling design needs to be introduced in the dies at the thick mass area /variable wall thickness where we are not having any scope in modification of product design to reduce the wall thickness of the part to avoid shrinkage porosity/high solidification time. Apart from solidification/cooling time we can reduce the Shrinkage porosity defect by optimizing the cooling channels from conventional cooling i.e. At which the cooling lines can be manufactured through conventional machining process to conformal cooling i.e. At which the cooling lines are manufacturing through 3D Printing process. Normally in the die-casting process the cavity area solidifies first after that the runner, overflows and biscuit solidifies. Soldification depends upon the thick mass area, where ever thick mass area is there then the solidification is complex.

Published in	International Journal of Mechanical Engineering and Applications (Volume 10, Issue 4)
DOI	10.11648/j.ijmea.20221004.12
Page(s)	53-58
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Conformal Cooling, Cooling Time, Solidification Time, Cycle Time Optimization, Shrinkage Porosity, Additive Manufacturing, Die Casting, Simulation

References

[1]	Wei Zhihao “Review of conformal cooling system design and additive manufacturing for injection mould”.
[2]	Ji soo Kim, Jun Kim, ju Yeon Lee “Die- casting Defect Prediction and Diagnosis system using process condition data.
[3]	ChaolinTan, Diwang “Design and additive manufacturing of novel conformal cooling molds.
[4]	E. A. Herman “Die casting Design Handbook”.
[5]	D. Dispinar and J. Campbell. Critical assessment of reduced pressure test. Part 1: Porosity phenomena. International Journal of Cast Metals Research.
[6]	Nawaz mahomed, Shrinkage porosity in steel sand casting: formation, classification and inspection.
[7]	P. W. Cleary, J. Ha, M. Prakash, T. Nguyen, 3D SPH flow predictions and validation for high pressure die casting of automotive components, Applied Mathematical Modeling.
[8]	Laws, K. J., Gun, B., Ferry, M., Effect of die-casting parameters on the production of high quality bulk metallic glass samples, Mater. Sci. Eng. 2006.
[9]	Shaochuan Feng, Design and fabrication of conformal cooling channels in molds.
[10]	Chunze Yan, Selective application of selective laser sintering technology.
[11]	Chun-Ting Lu, Application of conformal cooling to reduce cooling time and warpage of a U-shaped plate.
[12]	jadhav, santosh j jadhav, “investigation and analysis of cold shut casting defect and defect reduction by using 7 quality control tools”, international journal of advanced engineering research and studies..
[13]	S. Kamran afaq, Cycle time reduction in injection molding process by selection of robust cooling channel design.
[14]	Hardik Rathod, Prediction of shrinkage porosity defect in sand casting process of LM25.
[15]	patil sachin., naik girish., “defect minimization in casting through process improvement-a literature review”, journal of mechanical and civil engineering.

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APA Style

Boopathy Janarthanam, Rushikesh Nanasaheb Patil, Mayur Laxmanrao Jadhav. (2022). Design and Process Optimization in Die Casting Through Conformal Cooling. International Journal of Mechanical Engineering and Applications, 10(4), 53-58. https://doi.org/10.11648/j.ijmea.20221004.12

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ACS Style

Boopathy Janarthanam; Rushikesh Nanasaheb Patil; Mayur Laxmanrao Jadhav. Design and Process Optimization in Die Casting Through Conformal Cooling. Int. J. Mech. Eng. Appl. 2022, 10(4), 53-58. doi: 10.11648/j.ijmea.20221004.12

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AMA Style

Boopathy Janarthanam, Rushikesh Nanasaheb Patil, Mayur Laxmanrao Jadhav. Design and Process Optimization in Die Casting Through Conformal Cooling. Int J Mech Eng Appl. 2022;10(4):53-58. doi: 10.11648/j.ijmea.20221004.12

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@article{10.11648/j.ijmea.20221004.12,
  author = {Boopathy Janarthanam and Rushikesh Nanasaheb Patil and Mayur Laxmanrao Jadhav},
  title = {Design and Process Optimization in Die Casting Through Conformal Cooling},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {10},
  number = {4},
  pages = {53-58},
  doi = {10.11648/j.ijmea.20221004.12},
  url = {https://doi.org/10.11648/j.ijmea.20221004.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20221004.12},
  abstract = {This study aims to implement the conformal cooling in die casting dies to reduce the cycle time and rejections due to shrinkage porosity. In this paper we have done a flow simulation between conventional cooling and conformal cooling to optimize the cooling time/solidification time reduction and shrinkage porosity reduction in die casting parts where the thick mass area/high wall thickness occurs. In die casting process cycle time Solidification time plays a vital role. In order to optimize the die casting process cycle time, conformal cooling design needs to be introduced in the dies at the thick mass area /variable wall thickness where we are not having any scope in modification of product design to reduce the wall thickness of the part to avoid shrinkage porosity/high solidification time. Apart from solidification/cooling time we can reduce the Shrinkage porosity defect by optimizing the cooling channels from conventional cooling i.e. At which the cooling lines can be manufactured through conventional machining process to conformal cooling i.e. At which the cooling lines are manufacturing through 3D Printing process. Normally in the die-casting process the cavity area solidifies first after that the runner, overflows and biscuit solidifies. Soldification depends upon the thick mass area, where ever thick mass area is there then the solidification is complex.},
 year = {2022}
}

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TY  - JOUR
T1  - Design and Process Optimization in Die Casting Through Conformal Cooling
AU  - Boopathy Janarthanam
AU  - Rushikesh Nanasaheb Patil
AU  - Mayur Laxmanrao Jadhav
Y1  - 2022/08/17
PY  - 2022
N1  - https://doi.org/10.11648/j.ijmea.20221004.12
DO  - 10.11648/j.ijmea.20221004.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 53
EP  - 58
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20221004.12
AB  - This study aims to implement the conformal cooling in die casting dies to reduce the cycle time and rejections due to shrinkage porosity. In this paper we have done a flow simulation between conventional cooling and conformal cooling to optimize the cooling time/solidification time reduction and shrinkage porosity reduction in die casting parts where the thick mass area/high wall thickness occurs. In die casting process cycle time Solidification time plays a vital role. In order to optimize the die casting process cycle time, conformal cooling design needs to be introduced in the dies at the thick mass area /variable wall thickness where we are not having any scope in modification of product design to reduce the wall thickness of the part to avoid shrinkage porosity/high solidification time. Apart from solidification/cooling time we can reduce the Shrinkage porosity defect by optimizing the cooling channels from conventional cooling i.e. At which the cooling lines can be manufactured through conventional machining process to conformal cooling i.e. At which the cooling lines are manufacturing through 3D Printing process. Normally in the die-casting process the cavity area solidifies first after that the runner, overflows and biscuit solidifies. Soldification depends upon the thick mass area, where ever thick mass area is there then the solidification is complex.
VL  - 10
IS  - 4
ER  -

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Author Information

Boopathy Janarthanam

M. Tech, Mechanical Engineering, Deogiri Institute of Engineering and Management Studies, Aurangabad, India
Rushikesh Nanasaheb Patil

M. Tech, Mechanical Engineering, Deogiri Institute of Engineering and Management Studies, Aurangabad, India
Mayur Laxmanrao Jadhav

M. Tech, Mechanical Engineering, Deogiri Institute of Engineering and Management Studies, Aurangabad, India

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Plain Text BibTeX RIS

APA Style

Boopathy Janarthanam, Rushikesh Nanasaheb Patil, Mayur Laxmanrao Jadhav. (2022). Design and Process Optimization in Die Casting Through Conformal Cooling. International Journal of Mechanical Engineering and Applications, 10(4), 53-58. https://doi.org/10.11648/j.ijmea.20221004.12

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ACS Style

Boopathy Janarthanam; Rushikesh Nanasaheb Patil; Mayur Laxmanrao Jadhav. Design and Process Optimization in Die Casting Through Conformal Cooling. Int. J. Mech. Eng. Appl. 2022, 10(4), 53-58. doi: 10.11648/j.ijmea.20221004.12

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AMA Style

Boopathy Janarthanam, Rushikesh Nanasaheb Patil, Mayur Laxmanrao Jadhav. Design and Process Optimization in Die Casting Through Conformal Cooling. Int J Mech Eng Appl. 2022;10(4):53-58. doi: 10.11648/j.ijmea.20221004.12

Copy | Download

@article{10.11648/j.ijmea.20221004.12,
  author = {Boopathy Janarthanam and Rushikesh Nanasaheb Patil and Mayur Laxmanrao Jadhav},
  title = {Design and Process Optimization in Die Casting Through Conformal Cooling},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {10},
  number = {4},
  pages = {53-58},
  doi = {10.11648/j.ijmea.20221004.12},
  url = {https://doi.org/10.11648/j.ijmea.20221004.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20221004.12},
  abstract = {This study aims to implement the conformal cooling in die casting dies to reduce the cycle time and rejections due to shrinkage porosity. In this paper we have done a flow simulation between conventional cooling and conformal cooling to optimize the cooling time/solidification time reduction and shrinkage porosity reduction in die casting parts where the thick mass area/high wall thickness occurs. In die casting process cycle time Solidification time plays a vital role. In order to optimize the die casting process cycle time, conformal cooling design needs to be introduced in the dies at the thick mass area /variable wall thickness where we are not having any scope in modification of product design to reduce the wall thickness of the part to avoid shrinkage porosity/high solidification time. Apart from solidification/cooling time we can reduce the Shrinkage porosity defect by optimizing the cooling channels from conventional cooling i.e. At which the cooling lines can be manufactured through conventional machining process to conformal cooling i.e. At which the cooling lines are manufacturing through 3D Printing process. Normally in the die-casting process the cavity area solidifies first after that the runner, overflows and biscuit solidifies. Soldification depends upon the thick mass area, where ever thick mass area is there then the solidification is complex.},
 year = {2022}
}

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TY  - JOUR
T1  - Design and Process Optimization in Die Casting Through Conformal Cooling
AU  - Boopathy Janarthanam
AU  - Rushikesh Nanasaheb Patil
AU  - Mayur Laxmanrao Jadhav
Y1  - 2022/08/17
PY  - 2022
N1  - https://doi.org/10.11648/j.ijmea.20221004.12
DO  - 10.11648/j.ijmea.20221004.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 53
EP  - 58
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20221004.12
AB  - This study aims to implement the conformal cooling in die casting dies to reduce the cycle time and rejections due to shrinkage porosity. In this paper we have done a flow simulation between conventional cooling and conformal cooling to optimize the cooling time/solidification time reduction and shrinkage porosity reduction in die casting parts where the thick mass area/high wall thickness occurs. In die casting process cycle time Solidification time plays a vital role. In order to optimize the die casting process cycle time, conformal cooling design needs to be introduced in the dies at the thick mass area /variable wall thickness where we are not having any scope in modification of product design to reduce the wall thickness of the part to avoid shrinkage porosity/high solidification time. Apart from solidification/cooling time we can reduce the Shrinkage porosity defect by optimizing the cooling channels from conventional cooling i.e. At which the cooling lines can be manufactured through conventional machining process to conformal cooling i.e. At which the cooling lines are manufacturing through 3D Printing process. Normally in the die-casting process the cavity area solidifies first after that the runner, overflows and biscuit solidifies. Soldification depends upon the thick mass area, where ever thick mass area is there then the solidification is complex.
VL  - 10
IS  - 4
ER  -

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