Die casters usually carry out a die casting test before producing new castings. At the die-casting test stage, the runner and gate parts are always repeatedly corrected, which lead to a lengthened processing time and increased processing cost. In this study, a computer software was developed to calculate the gating system design with optimum gate and overflow positions for cold chamber High Pressure Die Casting (HPDC) die design by getting the part dimensions and choosing the suitable machine from a pre-defined database in the software. A design of experiment is used to formulate the objective function of the gate and overflow optimum position. At the end of this paper, a case study was developed as part of the software validation. The results show that the developed software can calculate the gating system design and eliminate the correction in the test stage.
HPDC Die casting Gating system Die casting design
This is a preview of subscription content, log in to check access.
Butler B (ed) (2001) Die casting handbook (2nd ed). NADCA, USAGoogle Scholar
Cleary PW, Ha J, Prakash M, Nguyen T (2008) Short shots and industrial case studies: understanding fluid flow and solidification in high pressure die casting. Appl Math Model 34:2018–2033CrossRefGoogle Scholar
Fuh JY, Wu SH, Lee KS (2002) Development of a semi-automated die casting design system. J Eng Manuf 216:1575CrossRefGoogle Scholar
Gulagoudar A et al (2015) Robust design approach to analyze casting defects in foundry industry. Adv Eng Appl Sci: An Int J 5(3):53–58Google Scholar
Hangai Y, Kitahara S (2008) Quantitative evaluation of porosity in aluminum alloy die castings by fractal analysis of spatial distribution of area. Mater Des 30:1169–1173Google Scholar
Hangai Y, Kitahara S (2008) Quantitative evaluation of porosity in aluminum die castings by fractal analysis of perimeter. Jpn Inst Met 49(4):pp 782–786Google Scholar
Kittur JK, Choudhari MN, Parappagoudar MB (2015) Modeling and multi-response optimization of pressure die casting process using response surface methodology. Int J Adv Manuf Technol 77:211–224CrossRefGoogle Scholar
Lee BD, Baek UH, Han JW (2012) Optimization of gating system design for die casting of thin magnesium alloy-based multi-cavity LCD housings. J Mater Eng Perform 21:1893–1903CrossRefGoogle Scholar
Lee WB, Lu HY (1999) Modeling of air black pressure in die-casting dies. J Mater Process Technol 91:264–269CrossRefGoogle Scholar
Park YK, Yang J-M (2011) Maximizing average efficiency of process time for pressure die casting in real foundries. Int J Adv Manuf Technol 53:889–897CrossRefGoogle Scholar
Queudeville Y, Vroomen U, Bührig-Polaczek A (2014) Modularization methodology for high pressure die casting dies. Int J Adv Manuf Technol 71:1677–1686CrossRefGoogle Scholar