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Improvement and validation of Zamak die casting moulds

2019Journal article Open access
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dc.contributor.authorPinto, H.A.
dc.contributor.authorSilva, F.J.G.
dc.contributor.authorMartinho, R.P.
dc.contributor.authorCampilho, R.D.S.G.
dc.contributor.authorPinto, A.G.
dc.date.accessioned2020-04-29T11:32:51Z
dc.date.available2020-04-29T11:32:51Z
dc.date.issued2019
dc.description.abstractThe automotive industry, like many other industries, uses a wide range of parts produced by the die-cast process. Parts like engine blocks, wheel spacers, alternator housings and command cable terminals, are made by die casting with different kinds of materials like aluminium and zinc alloys. Despite being a reliable process both in terms of quantity and quality, it is very important to keep the process parameters controlled, in order to achieve a minimum percentage of defective parts, which may be caused by several factors such as, porosities, segregations, incomplete fill, soldering, cracks, etc. The main goal of the die casting industry is to achieve the zero per cent defects target, a goal that goes along with the automotive industry and its quality system, and to accomplish this objective the stakeholders need to invest in research and development. In the casting industry, for instance, it is very important to have a complete knowledge of the entire process developed inside the casting machine, from the melting pot to the die, in order to obtain data so one can improve the filling parameters, machine parts, and moulds. The focus of the presented study is the improvement of the methodologies used to design moulds for control cable terminals in Zamak alloys. The work starts by characterizing the flow happening inside the mould at the moment of cavity fill by analysing computer fluid dynamics simulations (CFD). The study proceeds by quantifying the porosities detected on cut terminal surfaces, and the ultimate goal is achieved with the modification of molten metal flow systems, like channels and sprues, and the introduction of venting systems, with a resource to mathematical and geometrical calculus developed in MATLAB® specifically for that purpose. The paper ends with the validation of the improvements, by comparing the initial results with the ones obtained through an improved mould, building bases for novel design concepts of moulds for this kind of parts, as well as new studies trying to improve the results now achieved.pt_PT
dc.description.versioninfo:eu-repo/semantics/publishedVersionpt_PT
dc.identifier.doi10.1016/j.promfg.2020.01.131pt_PT
dc.identifier.urihttp://hdl.handle.net/10400.22/15920
dc.language.isoengpt_PT
dc.publisherElsevierpt_PT
dc.relation.publisherversionhttps://www.sciencedirect.com/science/article/pii/S2351978920301323pt_PT
dc.subjectDie castingpt_PT
dc.subjectZamak alloyspt_PT
dc.subjectMouldspt_PT
dc.subjectCFDpt_PT
dc.subjectComputing Fluid Dynamicspt_PT
dc.subjectDesign of mouldspt_PT
dc.subjectGas exhaustpt_PT
dc.subjectSimulationpt_PT
dc.titleImprovement and validation of Zamak die casting mouldspt_PT
dc.typejournal article
dspace.entity.typePublication
oaire.citation.endPage1557pt_PT
oaire.citation.startPage1547pt_PT
oaire.citation.titleProcedia Manufacturingpt_PT
oaire.citation.volume38pt_PT
person.familyNameSilva
person.familyNameCampilho
person.givenNameFrancisco
person.givenNameRaul Duarte Salgueiral Gomes
person.identifier1422904
person.identifier.ciencia-idB81C-4758-2D59
person.identifier.ciencia-id0314-43B9-03D4
person.identifier.orcid0000-0001-8570-4362
person.identifier.orcid0000-0003-4167-4434
person.identifier.ridI-5708-2015
person.identifier.scopus-author-id56870827300
rcaap.rightsopenAccesspt_PT
rcaap.typearticlept_PT
relation.isAuthorOfPublicationd050c135-4d9d-4fb2-97d1-cac97be3f6b9
relation.isAuthorOfPublication4decb370-eb85-4ee1-987f-ec328565ea07
relation.isAuthorOfPublication.latestForDiscoveryd050c135-4d9d-4fb2-97d1-cac97be3f6b9

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