Optimized development of Die Castings and Die Casting Processes Maheshwar N Morab MAGMA Engineering Asia Pacific Pte

Ltd INDIA Hyderabad 500029 Andhra Pradesh

Abstract The competitiveness of automotive casting development is strongly dependent on the "time to market", which has to be shorter and shorter. The process chain in the development of a die casting consists of functional design, digital mock up, detailed design, lifetime prediction, casting of prototypes, layout of the series casting process and tools, and the optimization of the series casting process. All these steps can be supported by CAE technologies such as CAD, FE analysis and casting simulation. An application of these technologies as distributed solutions already does support simultaneous engineering. But an enormous technical and economic advantage can be gained from the integration of these technologies, meaning the simultaneous exchange and usage of common models. An optimized development process, which is supported by a completely integrated chain of CAE technologies of 3D CAD, casting simulation and FE analysis, will be demonstrated using the example of a die cast automotive part. The generation, documentation and interpretation of results gained from FE analysis and casting simulation will be shown, as well as their integration into the development process.

Keywords Casting process simulation, CAE, process chain, high pressure die casting Introduction Metal casting process simulation has gained wide acceptance over the last several years. It has provided for the development of new die castings and for process optimization. Today, these tools are applied not only for structural parts or complex geometries, but also on components that appear less demanding but require good surface finish to meet customer requirements. The application of casting simulation is considered a driver of progress, offering new opportunities not only for metal casters, but for designers as well. The simulation program is supposed to deliver concrete statements on problems specifically related to high pressure die casting and to support the user to a great extent. The user guidance must be designed in a way that enables the user to gain proposals without having profound knowledge of the process and, on the other hand, enables the specialist to exactly reproduce "his process". The software module MAGMAhpdc (high pressure die casting) combines numerical simulation with the possibilities of an expert system. This basis will be developed in co-operation with the industry that uses the software.

Simulation - an up-front development and assessment tool The use of simulation will establish itself especially in the product development process. As soon as the first product design is available, the first simulation calculations can be carried out. At that time, the greatest optimization potential is at the designer's disposal, as he can exert the greatest influence on his construction at this early stage. Already during this first phase, simulation can support the process and construction failure mode and effect analyses (FMEAs) efficiently. At this stage, the product can still be optimized with a minimum of time and resource allocation. The metal caster and toolmakers' input should also leave their marks on product development at an early stage to ensure the realization of the best possible compromise. This way, the communication between the design engineer, the toolmaker, the metal caster and those responsible for quality reaches a new level with the possibility of achieving optimized solutions in a timely manner, Figure 1.

compromise regarding the casting compromise regarding the casting deadline price function mounting solidity weight producibility durability maintenance/repai r casting space tolerances quality design

Figure 1: Compromises immanent in the design of a casting: A casting must meet various demands. Often these demands are contrary to each other. An optimum casting distinguishes itself by meeting the essential requirements of the design engineer and at the same time assuring the "castability of the component.

It is necessary to develop an efficient "closed loop" of design experience, simulation capability and process knowledge as the basis of successful simultaneous engineering. Also the results gained from the production process must be taken into account much more strongly than has happened in the past. Design modifications of a casting required for optimization, require a close and trusting cooperation between designer and metal caster. Simulation provides a visual link for effective engineering communication between these two important entities. At this critical juncture, the development of casting simulation as an expert system meets the casting designer's demands by enabling him to carry out iterations to optimize his design as well as to verify requests for changes from the production requirements. Simulation is able to support not only the design stage, but also a systematic optimization of a casting process to meet all requirements. MAGMAhpdc - Simulation software for high pressure die casting In addition to the calculations of mold filling, solidification, residual stresses and casting distortion that are available in MAGMASOFT, several dedicated capabilities have been developed that are specifically related to high pressure die casting. After entering the casting geometry or loading existing CAD data, you can determine the casting parameters for die filling. The high pressure die casting calculator integrated in MAGMAhpdc delivers die filling conditions specifically related to your casting based on extensive theoretical knowledge and practical experience. The procedures of setting up the casting and die lay-out will be demonstrated at two below two examples, an Aluminum flange part with high demands on surface quality and pressure tightness and a complex Magnesium structural used as a GPS bracket in a car.

Figure 2 (a): Aluminum Flange casting

Figure 2 (b): Magnesium - GPS Bracket

Selection of an appropriate die casting machine For any casting to be investigated, the process layout in MAGMAhpdc starts with the Selection of an appropriate die casting machine. During this selection, the necessary closing force and the available flow rate of the machine depending on the desired casting quality are very important.The necessary closing force is the product of the projected area of the casting and the intensification phase that has to be realized to obtain th required casting quality. The projected areas are available immediately after the automatic enmeshment by MAGMAhpdc. A machine can only be selected from the database if it meets the closing force requirements, Figure 3.

Figure 3: Selection of a suitable die casting machine after determination the desired specific metal pressure. The necessary closing force is calculated and can be provided with an additional safety pressure increase. Only machines that show this closing force can be selected from the database for simulation.

The next step is to verify if the machine is able to produce the required flow rate during the second shot phase. The required flow rate is mainly determined by the die filling times, which must be kept to, in connection with the flow resistance and the used alloy. This is why we included a flow rate evaluation for die casting machines in MAGMAhpdc. The characteristic wall thickness of the casting defines the allowable die filling time. Calculating the die filling time from the ingate The die casting machine's flow rate depends mainly on the prevailing hydraulics.The flow resistances define the balance between the hydraulic system and the die cavity. In this view, the ingate constitutes the ruling flow resistance. The evaluation result is visualized in the shape of a PQ diagram, see Figure 4. The diagram shows the user the allowable working area below the machine's characteristic line. The process point must lie within this area. In addition, the diagram contains a straight line representing the optimum exhaustion of the machine's capacity

Fig. 4: PQ diagram - The limitations of the recommended working area (marked gray) are marked by the maximum and minimum gate velocities specifically related to the casting (horizontal lines) and by a maximum allowable die filling time (vertical line).

The process point for the defined parameters is marked correspondingly. This way of visualization enables the user to optimize this process point quickly by changing parameters, as the visual control of all executed modifications is possible at any time.

Process point calculation If the selected machine's flow rate is not sufficient, the user can select a more powerful machine or try to change the conditions so that the machine's capacity will not be exceeded, for example by changing the plunger diameter, the cross-sectional area of the ingate, etc. Velocity of the first phase As known from numerous research work, the first phase is a very important process step, but in praxis still often underestimated. If the velocity of the first phase is not well chosen, waves may be overtopping or be reflected repeatedly between the die wall and the plunger head. In both cases, gases will already be entrapped by the melt in the shot chamber and then be conveyed into the cavity. These gases can be found within the casting later on. In practice, a very slow first phase is realized for dies that are not subject to forced venting to prolongate the escape time that the gas volume needs to escape from the die. In many of these cases, the problem of wave formation is not taken into account. A software originally been developed at the Ohio State University, USA, has been integrated into MAGMAhpdc. It suggests a suitable shot profile for an optimum first phase. The plunger is moved forward depending on an initial acceleration, Figure 5.

Figure 5: Velocity profile for an optimum first shot phase - The casting quality can be influenced by selecting the shot profile of the first shot phase. Wave reflections within the shot chamber due to a too low plunger velocity and wave overtopping in front of the plunger due to too high plunger velocity lead to an unavoidable entrapment of gas occlusions into the cavity, and therefore to uncontrolled gas occlusions within the casting. In the upper half of the image, shows an optimum shot profile of the first phase, which avoids wave overtopping. In lower half of the image, the wave formation is animated.

The classic arrangements, constantly accelerated first phase or first phase with constant velocity, can also be taken into account during simulation. Also with these, the resulting velocity or acceleration values that lead to acceptable first phases are displayed. Switch point The casting quality can strongly be influenced through a good positioning of the switch point. The rule of thumb is that the velocity of the second phase should be reached at the ingate. MAGMAhpdc allows a process definition with random switch point position. This way, it is possible to study the effects of different process definitions on the screen and to define an appropriate process window before starting the production, Figure 6.

Figure 6: The process definition is subdivided into three sections. In the first section on the left, the program makes a proposal for a sensible process definition. For the moment, this proposal also appears on the right. In the right section, the user can modify this proposal in the colored fields. The third section at the bottom is used to visualize the process parameters.

Vacuum Dies subject to forced ventilation are normally used to produce die castings that meet the greatest demands. This way, it is possible to produce heat-treatable and weldable die castings. During evacuation of air or ventilation, three different ventilation situations can be taken into account in MAGMAhpdc:

1. Vents from the cavity to the surroundings. 2. Vacuum systems that are activated when the plunger has passed the filling orifice. A time dependent vacuum profile appears at the exhaust valve. 3. Running and gating systems of which the die and the shot chamber are evacuated before proportioning is carried out and the shot is started.

Shot profile The concept of optimum user support is also realized in the visualization of the shot profile. The display contains two pairs of curves with one curve each representing the volume flow and one representing the plunger position, both being functions of time. The proposal made by MAGMAhpdc is compared to the parameters modified by the user. Deviations are graphically displayed, and the user can verify his input and correct it if necessary, Figure 7.

Figure 7: Shot profiles proposed by MAGMAhpdc (green and yellow) compared to shot profiles defined by the user (red and blue). The shot profiles show the plunger position and the current plunger velocity, both of which are time dependent.

The high pressure die casting calculator supports the user during the definition of useful process parameters for die filling. This enables the expert to define the ingate and die filling parameters universally and without using further aids. But also users who are not working frequently on the actual casting process are able to get quick and easy access to field-proven casting simulation. The casting cycle Besides the die filling simulation parameters from the high pressure die casting calculator, further information is needed for the complete calculation of the casting process. To define a quasi-stationary temperature field within the die, several casting cycles can be calculated, as the die filling and solidification behavior is strongly dependent on the die's temperature field. The number of cycles to be simulated can be chosen at random. The calculated result from a cycle is the starting condition for the next cycle. The information on the chronological control of a casting process (locking time, side core pulling time, ejection time, spraying time, proportioning time, cooling and heating time, etc.) can be defined at random. Additionally, the software is able to control these processes automatically after temperature limits have been defined. The cooling system can be exactly simulated. Besides the random choice of the cooling medium (water, oil, air, etc.) for each individual vent, a time dependent or temperature dependent control is possible. In addition to the cooling and heating system, the exact representation of the spraying process is an essential basis for the exact calculation of the die's thermal economy. In addition to the timing of the spraying process in the total cycle time, the user can use parting powder on the different tool parts over different periods of time. It is also possible to define wait times (e.g. by moving the spray arm) and a consequent air blow through compressed air. In this case too, it is possible to define automatic control by entering the desired temperature limits.

MAGMA database To gain meaningful simulation results, it is necessary to know the material properties depending on the respective temperature (thermophysical data). For this purpose, an extensive material database is put at the user's disposal. This database contains all standard alloys used in high pressure die casting processes. Values of density, thermal conductivity, heat capacity and latent heat of fusion as well as information on flow and solidification behavior and characteristic material values have been stored in the database among other things. During process definition, this information is simply read from the database. But there are even more possibilities provided by the database included in the software. For example, the machine data of common die casting machines have been stored. Frequently used geometries can be saved and used for any new project. This enables the user to use specific standards for shot chamber sizes, overflow wells, vacuum valves, etc., at a minimum labor consumption. The calculations of heat transfer coefficients for die cooling dependent on the runner's length, the diameter and the flow rate, have also been realized within the database. Using the existing data stock, the user can carry out professional simulation calculations immediately. It is also possible to enlarge the data stock by adding the user's own existing values at any time.

Results The knowledge gained from simulation can be applied earlier and more in-line with casting construction, die layout and production demands if it is combined with still required professional knowledge and experience. The new possibilities are shown at the example of two different types of die castings as introduced in Figure 2 in the following.

Die filling simulation During the simulation of the die filling process, the temperature, the velocity, the flow direction and the pressure within the melt are calculated for each filled area of the casting at any time. Viewing the die filling progress can already recognize possible defects. Fig. 8 shows the temperature distribution of the Mg die casting within the melt at different times It becomes obvious that gases between two flow fronts cannot escape via the die parting.

Figure 8: Die filling behavior and temperature distribution of the Magnesium GPS bracket - The progress of die filling at different stages shows the danger of gas entrapment in the casting The gas pressures calculated at the end of die filling clarify this statement, see Figure 9. Gas inclusions have to be expected within the bosses. Areas with likely gas inclusions become very important when a casting is to be subject to heat treatment. Comparisons drawn between heat-treated die castings have shown very exact localized correspondences of calculated high gas pressures and gas bubbles within the casting. Through simulation with changed venting conditions, knowledge could be gained that has considerably reduced expensive die modifications and casting tests.

Figure 9: Prediction of gas entrapment through visualization of air pressures.

In addition to the evaluation of different die filling sequences, the quickest way to position an optimum venting as well as overflows is to use the local die filling time, Figure 10. It is known from experience that the areas filled last are the areas of most effective venting, because the vent cross sections are not closed prematurely by melt. When dies are used that are not subject to forced venting, these areas are the optimum areas for overflows. Figure 10: The display of die filling time shows casting regions filled early marked blue. Wells and vents should be positioned in the yellow regions that are filled last to be most effective.

The danger of cold shuts can be evaluated by analyzing the temperature distribution during the die filling process. As soon as the temperature of the die filling progress falls below the liquidus temperature, cold shuts can be expected. Such defects can be detected very quickly in MAGMASOFT. The velocity display can also be colored, just like the temperature display. In addition, it is possible to visualize the respective direction using vectors. Critical velocities can be marked separately.

A special criterion visualizes die areas that contain risks of die erosion due to high flow velocities. Another interesting topic is the visualization of velocities during the entire die filling process using control points. In a die casting with several ingates, a measuring point has been positioned in each ingate. The evaluation, Figure 11, shows that there is a different flow velocity in each ingate. The exact time at which the melt arrives at the ingate can be read simultaneously. Important remarks on the optimization of the running and gating system are given as well.

maximum

Figure 11: Courses of velocity in different ingates. The maximum in one ingate is 3 times as high as the normal velocity. This is caused by unfavorable flow conditions within the runner.

Another way of evaluating the die filling process is to use tracer particles for display. Tracer particles are particles of which the traveled distance is visualized during the entire die filling. This makes it easier to recognize swirls and turbulences. Figure 12 shows tracers in the ingate area of a casting. A swirl in the runner is visible. This means that a danger of gas occlusions exists even before the melt enters the cavity. The runner should be optimized. Figure 12: Tracer particles visualize swirls and turbulence. The colored area represents the time at which the particles enter the die cavity.

Solidification simulation Especially in high pressure die casting processes, the correct evaluation of solidification behavior is only possible after accurate die filling simulation, as a considerable temperature loss occurs during die filling, thus causing high temperature gradients in the filled casting. The solidification simulation allows to evaluate the solidification behavior of the casting and defects that may result from it. Thanks to the simulation of the entire die, statements on the die's thermal economy are available at any time, lay-out of the Mg die casting see figures 13.

Figure 13: Thermal lay-out of the die for the Magnesium die casting Analogous to die filling simulation, the temperatures of all parts of the casting and the mold are calculated at any time during solidification simulation. Of course, the heat dissipation through the cooling system and through the surroundings as well as the released solidification heat are taken into account for calculation. Corresponding to the die filling results, various evaluation methods are also available for the solidification process. Besides the die casting's course of solidification, a large number of physical quantities and criterions is calculated. The most important parameters are: cooling rates, temperature gradient, solidification time, the HOTSPOT criterion, but also feeding and porosity criterions. For example the criterion identifying any hot spot is shown in Figure 14. The solidification time gives an overview of the entire die casting within one image. Because of that, also statements on the necessary minimum die locking time are possible with new castings. While optimization measures are carried out, the possible need for additional cooling can be determined. The hotspot criterion detects automatically the critical areas for solidification, and therefore points out possible problems to the user.

Figure 14: The hot spot criterion identifies any casting region that contains possible defects due to solidification shrinkage.

The Die Just as for the casting, the temperature field is also calculated for the die during the entire die casting cycle. This is an obligatory requirement for the exact calculation of the melt's thermal behavior during die filling and solidification. The optimization of the cooling process is only possible if the temperature distribution is known for the entire die at different times. Critical areas in the die can be located simultaneously for the respective casting (overheated areas - soldering spots and sink marks; undercooled areas - danger of cold shuts). Figure 15 shows the temperature distribution in the bottom core and in one side core for the die of the flange part at the time of ejection. Overheated die areas can be clearly recognized by their white color.

Figure 15: The die shows very high temperatures in thin die areas (white) at the time of ejection. In this case, die care is a very important operation that helps to avoid soldering spots.

With the aid of "virtual" thermocouples, Fig. 16, the entire thermal behavior of the die can be evaluated efficiently. At the same time, it is possible to check the temperature at locations that cannot be reached or are very difficult to reach through measuring method in practice. Figure 16: The display of temperature as a function of time provides information on the die's thermal behavior for all calculated casting cycles.

Residual stress calculation for die castings Each die casting shows temperature differences during ejection that are caused by different wall thicknesses, Figure 17. During the following process of cooling down to ambient temperature, the casting shrinkage varies at different points due to these temperature differences. The result is the formation of residual stresses in the casting and the deformations that result from these. In MAGMASOFT , residual stresses and deformations can be calculated using the "thermal history" of the casting. Figure 18 shows the residual stress according to von Mises.

Figure 17: The casting shows significant temperature differences at the time of ejection. In the present case, there are differences of more than 140 C. During further cooling, these temperature differences lead to residual stresses within the casting. Figure 18: The calculated reduced stress according to von Mises. The highest stresses occur within the thin flange. The stress simulation can also be used to calculate the thermal condition of the die during production. It is possible to calculate die distortion and to minimize it by carrying out concerted heating and cooling processes, see Figures 19 and 20. Figure 19: The temperature profile of the die leads to thermally conditioned deformations. The die distortion is displayed 50 times exaggerated for a better visualization.

Figure 20: Reduced stress according to von Mises for one die half. - The temperature shock caused by the hot melt leads to high stresses in die surface areas (displayed in light colors). The thin, circumferential web shows the highest stresses and is therefore very much endangered by fire cracks. During die construction, critical functional parts can already be provided as exchangeable inserts.

Linking the process to the components design More and more casting designers are interested in taking the process into account during their design stages. Predicted residual stresses or material properties in MAGMASOFT can be transferred into FE codes for performance simulation. This enables the designer to accurately predict the performance of the component during application.

Figure 21: Data transfer of process relevant information to FE design codes for Load simulation, here shown at the example of solidification times mapped on a IDEAS mesh. Summary These new developments combining more traditional simulation methods with process specific capabilities provides engineers with all the necessary support concerning the definition of useful process parameters, from hpdc machine selection to venting conditions. The experienced metal caster is able to carry out a general definition of the ingate and die filling parameters without using further aids. But also users that are not confronted with the actual casting process every day gain access to practical casting simulation. This goes especially for casting designers and tool makers who want to construct a casting suitable for production. In both cases, enormous costs can be saved at the beginning and during production by using casting simulation for casting development and die production. Some possibilities of die filling, solidification and stress simulation in high pressure die casting processes have been described using a real die casting. It is always important to take the correlations between different results into account. The variety of factors influencing the casting quality cannot be described by one single result. Complex results and the possibilities of graphical representation are useful for the complete evaluation of the die casting process. Bibliography
1. Herman, E.A., "Die Casting Process Engineering and Control", Society of Die Casting Engineers, Inc., River Grove, Illinois 60171, 1988. 2. E. Flender, D. M. Lipinski, W. Schfer, "Numerical Modeling of the Filling Sequence and Solidification of Castings", Modeling of Casting, Welding and Advanced Solidification Processes V, Palm Coast Florida, 21.-26.03.1993, Edited by T.S. Piwonka, V. Voller, L. Katgermann, The Minerals, Metals & Materials Society, 1993 3. R. H. Box, L. H. Kallien, "Rechnergesttzte Formauslegung und Prozesimulation beim Druckgieen", Sonderdruck aus Giesserei Heft 10, 1995 L.H. Kallien, R. Rsch, H.H. Becker, S. Kluge, "Simulation Aided Design and Process Development for Magnesium Die Casting", Die Casting Engineer, 1998 5. H.-G. Haldenwanger, R.Rsch, "Entwicklungsstrategien mit alternativen Werkstoffen - Leichtbau im Fahrzeugbau am Beispiel Magnesium", Giesserei-Praxis 2, 1998 6. C. Rosbrook, R. Kind, "Casting Process Simulation of Stresses and Distortion in Castings and Dies", Die Casting Engineer 1999, September/October,1999 7. R. Seefeldt, L. Gansauge, "Zukunftssicherung des Druckgieverfahrens mittels Simulation", Pre-sentation on the EUROGUSS 2000 show, Sindelfingen, Germany