Autonomic Optimization in High Pressure Die Casting – Simulation Was Yesterday

In the past
For more than 5, 000 years metal has been company, turning raw ore into usable tools. At first the castings were limited to very simple and small structures, but nowadays we see castings analyzing anything from an ounces to thousands of pounds. New casting processes developed over the last hundred or so years allows modern casters to produce very skinny and complex castings that can be made with predetermined quality characteristics at levels well below the visual. These are not single castings produced in a laboratory; these are mass productions with day tolerances for dimensions, wheat structures, mechanical properties and strength. zinc die casting

19th Century
Actually, casting was limited to gravity pouring of chemical metal into a mold. In the nineteenth hundred years, a more mechanical spreading approach was developed. The first die casting-related particular was granted in 1849 for a tiny hand controlled machine when it comes to mechanized printing images type production (1), the forerunner of today’s high pressure die casting machines.

In the high-pressure cease to live casting, process liquid metallic is not poured by gravity into a yellow sand mould, but forced by high pressure into a steel die. The good thing about this technique is that it is the shortest way from liquid metal to a final product. Casting wall space can be very slim and most dimensions do not have to be machined following the casting process. Hundreds of thousands of castings can be made from a single cease to live, keeping the costs low and the quality high.

Where there is light there exists shadow. The advantages are bought by a costly investment in the die casting machine and related equipment and the die in particular, high quality steel in which the casting shape, a melt feeding system (runner) and cooling lines are machined into. Finding the right die design satisfying its purpose required a lot of experience of the responsible engineers, as well as intensive endeavors using trial and mistake.

21st Century
There has been tremendous progress in modernization and improvements in high pressure die audition during the last years, including computerized sprayers and casting extraction systems, more efficient melting furnaces and pouring devices, better handled die-casting machines and digital monitoring systems. All these improvements made die audition processes more efficient, better controllable and helped producing higher quality castings.

By the same time, yet , today’s die casting industry is facing challenges early on casters did not see. Experienced metalcasters are moving into retirement – yet at the same time, many shops are having difficulty in recruiting young engineers to train as replacements. The demand for high quality standards for the castings, international competition, customer demands for lower prices and the difficult monetary situation across the globe, all impact the bottom line and company profit margins. Put to this the increasing need to shorten product development times requires that the caster produces good castings the first time, or the cost composition to generate income is in threat.

Process Simulation
Toward the final of the 1980’s, process simulation was introduced to the field of cease to live casting. Process simulation allows the metalcaster (or developer or engineer) to make a simulation of the part to be solid, predict possible outcomes structured on input variables, and optimize those outcomes by using the processing electrical power of the pc, somewhat than the traditional experience-based trial-and-error methodology. With the dawn of the personal pc computer and workstations on every desk, process ruse became available to every engineer. Maintained Computer Made it easier for Design (CAD) systems quantity models could be created fast and stay used as direct input for ruse.

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