A method for yield and cycle time improvements in Al alloy casting with enhanced conductivity steel for die construction

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Review Pub Date : 2022-01-01 DOI:10.1051/mfreview/2022017

A. Vergnano, Emanuele Salvati, A. Magistrelli, Edoardo Brambilla, P. Veronesi, F. Leali

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引用次数: 1

Abstract

A die for Al alloy casting must be designed to achieve the expected quality levels. Moreover, the casting unit cost must be regarded as the objective function to be minimised. It can be expressed as a function of the quantity of materials and energy to be used, cycle time and equipment investment. This work compares the performance of the die with inserts manufactured using the usual 1.2343 steel with that of the innovative 1.2383. The latter is considered due to its enhanced thermal conductivity, despite being more expensive. Simulation experiments are designed to evaluate different die layouts. The quality design solutions are evaluated against the cost objective function in order to identify the optimal die choice. A case study on gravity die casting (GDC) of an AlSi7Mg0.3 engine head shows faster solidification dynamics when using 1.2383 instead of 1.2343 steel. This reduces the feeder volume, thus increasing the production yield and speeding up the cycle time with a leverage effect. The higher investment cost for the inserts is rapidly returned thanks to the reduction in variable costs. The Return On Investment (ROI) with the improved die in the new solution is short compared with the life of the die.

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一种用增强导电性钢提高铝合金铸件成品率和周期时间的方法

铝合金铸件的模具设计必须达到预期的质量水平。此外，必须将铸造单位成本作为最小化的目标函数。它可以表示为要使用的材料和能源的数量，周期时间和设备投资的函数。这项工作比较了使用通常的1.2343钢与创新的1.2383制造的刀片的模具性能。后者被认为是由于其增强的导热性，尽管更昂贵。设计了仿真实验来评估不同的模具布局。根据成本目标函数对质量设计方案进行评估，以确定最优的模具选择。对AlSi7Mg0.3发动机机头重力压铸(GDC)的实例研究表明，使用1.2383钢代替1.2343钢时，凝固动力学更快。这减少了给料器体积，从而提高了生产产量，加快了循环时间，具有杠杆效应。由于可变成本的降低，较高的投资成本很快得到了回报。与模具的使用寿命相比，改进后的模具的投资回报率较低。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Manufacturing Review ENGINEERING, MANUFACTURING-

CiteScore

5.40

自引率

12.00%

发文量

审稿时长

8 weeks

期刊介绍： The aim of the journal is to stimulate and record an international forum for disseminating knowledge on the advances, developments and applications of manufacturing engineering, technology and applied sciences with a focus on critical reviews of developments in manufacturing and emerging trends in this field. The journal intends to establish a specific focus on reviews of developments of key core topics and on the emerging technologies concerning manufacturing engineering, technology and applied sciences, the aim of which is to provide readers with rapid and easy access to definitive and authoritative knowledge and research-backed opinions on future developments. The scope includes, but is not limited to critical reviews and outstanding original research papers on the advances, developments and applications of: Materials for advanced manufacturing (Metals, Polymers, Glass, Ceramics, Composites, Nano-materials, etc.) and recycling, Material processing methods and technology (Machining, Forming/Shaping, Casting, Powder Metallurgy, Laser technology, Joining, etc.), Additive/rapid manufacturing methods and technology, Tooling and surface-engineering technology (fabrication, coating, heat treatment, etc.), Micro-manufacturing methods and technology, Nano-manufacturing methods and technology, Advanced metrology, instrumentation, quality assurance, testing and inspection, Mechatronics for manufacturing automation, Manufacturing machinery and manufacturing systems, Process chain integration and manufacturing platforms, Sustainable manufacturing and Life-cycle analysis, Industry case studies involving applications of the state-of-the-art manufacturing methods, technology and systems. Content will include invited reviews, original research articles, and invited special topic contributions.