Derivation of Plunger Injection Input to Prevent Gas Defects by Algebraic Approach for Aluminum Alloy Diecasting

Abstract

Die casting has many advantages, such as high precision, mass production, and excellent recyclability. However, gas defects in the product have become a problem. One countermeasure to this problem is to design the injection input of the plunger appropriately. Recently, CFD has been used to design plunger injection inputs, and by combining with optimization techniques, auto-design of plunger injection inputs has been possible. However, CFD is difficult to apply because of the high cost of CFD resources, the need to resource IT engineers, and the time required for its auto-design. Therefore, we propose a new injection input design method based on an algebraic approach, enabling anyone to design a plunger injection input that prevents gas defects with ease and at a low cost. Simulation and experimental results verified the effectiveness of the proposed method.