Abstract
In high pressure die casting processes, a die plays a critical role in removing heat from the molten metal during the cavity filling and solidification stages. Proper control of die temperature is essential for producing superior quality components and yielding high production rates. In this paper, a computerized intelligent real-time monitoring and control system (IRMCS) is developed for die casting processes involving cooling of a die with multiple channels. A local temperature controller is designed to monitor temperature signals from the die insert and flow rate signals from the cooling lines. The performance of the controller is evaluated, and the effect of the controller on local temperature and heat transfer of casting dies is analyzed. The experimental results obtained from a laboratory die casting process simulator indicate that the developed control system is capable of adjusting the desired supply of cooling water into multiple cooling lines, which effectively controls the local temperature of the die insert within a given range. Hence, the desired thermal pattern of the die becomes achievable.
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Acknowledgements
The authors would like to take this opportunity to thank Natural Science and Engineering Research Council of Canada (NSERC) and Ryobi Die Casting (USA) Inc. for supporting this work. One of the authors (T. Yang) wishes to acknowledge the Government of Ontario and University of Windsor for financial support in the form of an Ontario Graduate Scholarship.
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Yang, T., Hu, H., Chen, X. et al. Thermal analysis of casting dies with local temperature controller. Int J Adv Manuf Technol 33, 277–284 (2007). https://doi.org/10.1007/s00170-006-0468-8
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DOI: https://doi.org/10.1007/s00170-006-0468-8