A development of virtual prototyping manufacturing system for high pressure die casting processes

摘要

High pressure die casting (HPDC) magnesium components are increasingly used worldwide in these few years because of the excellent properties that magnesium alloys can offer meet the new product requirements. With the increasing worldwide application for the use of magnesium parts, there are many research and development projects targeted at advancing the technologies of HPDC have been carried out. However, the real optimized mold design and production of defect free castings remains a challenge for die casters. For many HPDC magnesium products, especially the case with porosity-free and highly cosmetic requirement, the challenge not only comes form lacking of detail understanding of how molten magnesium alloys fill mold cavity and form defects but also from improper preliminary part design. A virtual prototyping system integrating several software and hardware that can be served as an effective tool for both part and mold design engineer in evaluating the part manufacturability is proposed in this study. Also, the major cause of defects that is the predominant cause of rejection for thin walled, highly cosmetic requirement and leaking-free magnesium parts are investigated in this study.