The die casting process is well established in the foundry industry. Nevertheless, there are still several challenges present, e.g. the entire control of mold filling. Detailed information about the filling level and the melt condition during the filling is highly favorable for optimizing both, the process and the quality of produced parts. The opacity of the mold in combination with short process times, high pressures and temperatures make the direct observation of the mold filling impossible. Numerical simulations help to visualize the melt flow as well as the thermal conditions during mold filling. However, on this way an assertion of the actual mold filling in the production of each casting is not possible. An opportunity to gather information of mold filling during the production process is to use suitable sensors which are directly positioned in the cavity. The present work analyzes opportunity of the observation of mold filling during high pressure die casting (HPDC) through the alignment of experimental sensor data and numerical results. The sensor data describe the level of mold filling during the casting cycle. This enables the depiction of the mold filling as a function of experimental process parameters such as process time, piston position, crucible temperature, dosing weight and thickness of the castings.
展开▼
