Optimum Velocity Control of Die Casting Plunger Considering Air Entrainment

Abstract

  Die casting is adequate for mass production and has the advantage of being able to yield complicated shapes accurately. One defect of die casting for high-speed injection molding, however, is the occurrence of air entrapment. To avoid air entrapment, velocity control of the plunger has proved to be very effective. In this paper, fluid behavior and the quantity of air entrapment caused by a die casting plunger movement are analyzed using CFD. The optimum velocity control input of die casting plunger is calculated in order to reduce and prevent air entrapment in die casting products. Optimization is performed by a genetic algorithm incorporating the CFD simulator.