Abstract
In vacuum die casting, we require a high quality die design for fuel cell bipolar plates to prevent unfilled phenomena, turbulent flow, and porosity. We have designed a die for thin plate die casting using two geometric shapes. In addition, we propose a new overflow system based on numerical simulation, and conducted actual vacuum die casting experiments. An optimal die design consists of seven overflows at the end of the cavity and three overflows at each side wall of the cavity. In our experiment, the molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and are uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. To validate the proposed approach, a good quality sample was manufactured using the optimal die design with the proposed overflow system.
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Chung Gil Kang, who received a Ph.D. at Tohoku University in 1987, has been a professor in the School of Mechanical Engineering of Pusan National University since 1985. His interests are semisolid material of manufacturing processing, metal matrix composite, casting/forging technology, cold/hot press forging, hybrid material forming.
Chul Kyu Jin received an M.S. degree at Pusan National University in 2012. Jin’s interests are in semi-solid process, die casting process, rubber forming, thin sheet stamping and fuel cell bipolar plate.
Chang Hyun Jang received an M.S. degree at Pusan National University in 2013. Jang’s interests are in aluminum forging, semi-solid forging and cold/hot press forging of automobile parts.
Dae Up Kim, who received a Ph.D. at Osaka University, has been a principal researcher in Environment Material & Components Center of Korea Institute of Industrial Technology since 2009. His interests are light materials and new technologies of automobile parts.
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Jin, C.K., Jang, C.H. & Kang, C.G. Die design optimization of die casting for fabrication of fuel cell aluminum bipolar plate with micro-channel through casting simulation and experimental investigation. J Mech Sci Technol 27, 2997–3003 (2013). https://doi.org/10.1007/s12206-013-0816-1
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DOI: https://doi.org/10.1007/s12206-013-0816-1