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Improving the quality of die castings through optimal plunger motion planning: analytical computation and experimental validation

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Abstract

High-pressure die casting is a process widely used to manufacture components with high productivity and dimensional accuracy. Its main disadvantage is the high percentage of scraps, due to a high amount of defects. Thus, the identification of the parameters affecting quality of castings is the current challenge towards an efficient and effective production. In their previous work, the authors have found and statistically validated a novel parameter explaining and forecasting both static mechanical properties and porosity of castings. Such a parameter, defined as the root mean square value of the plunger acceleration in the fast shot stage, represents a measure of the average force transmitted by the plunger to the melt and has been proved to be very effective in predicting casting quality. In order to provide a practical tool for the use of this parameter, this work proposes an analytical method for its computation, starting from the plunger displacement curve or just some notable points. The method formulation takes advantage of the analytical development of the typical motion primitives adopted and also accounts for limitations due to the machine. Hence, the optimization of the process can be achieved by selecting in advance the most suitable plunger motion profile, among those feasible, that allows to improve the casting quality. Besides the theoretical formulation, a meaningful experimental validation is provided to demonstrate the correctness of the proposed parameter and of the analytical approach, as well as its ease of implementation that makes it suitable for industrial applications.

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Authors and Affiliations

  1. Department of Management and Engineering, University of Padova, Stradella S. Nicola 3, I-36100, Vicenza, Italy

    Elena Fiorese, Dario Richiedei & Franco Bonollo

Authors
  1. Elena Fiorese
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  2. Dario Richiedei
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  3. Franco Bonollo
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Correspondence to Elena Fiorese.

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Fiorese, E., Richiedei, D. & Bonollo, F. Improving the quality of die castings through optimal plunger motion planning: analytical computation and experimental validation. Int J Adv Manuf Technol 88, 1475–1484 (2017). https://doi.org/10.1007/s00170-016-8875-y

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  • DOI: https://doi.org/10.1007/s00170-016-8875-y

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