Prediction of Flash by Computer Simulation of Die Distortion in High-Pressure Die Casting of JIS ADC12

Abstract

  The thickness and position of flash in the high pressure die-casting of a flat shape part was analyzed by FEM. The temperature distribution of the die was determined by FDM cast simulation, and the thermally generated gap between the movable die and stationary one was predicted. The distortion of the whole die-cast machine as well as the die was calculated. The effect of the internal pressure on the gap during injection was evaluated as hydrostatic pressure exerted on the die-cavity. The position and thickness of flash were found to be directly correlated with those of the predicted gap because these were well coincided with those observed in the actual part. The flash thickness corresponded to gap thickness when injection speed was decelerated by plunger braking at the hydrostatic pressure value of 20MPa, and at 60MPa without the braking. It was concluded that the developed simulation method can predict the position and thickness of flash with sufficient accuracy.