Messung und Simulation des Verzugs von Druckgussbauteilen

Translated title of the contribution: Measurement and Simulation of Distortion in High-Pressure Die-Castings

Peter Hofer

Research output: ThesisDoctoral Thesis

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Abstract

In this work the influence of the casting parameters during the high-pressure die-casting process on the global, macroscopic distortion of two trial castings with quantitatively predictable distortion behaviour were determined. The results of the measured distortion values of trial castings and the results of numerical simulation were compared quantitatively using the software package ANSYS Workbench. In the first instance two high-pressure die-casting dies were designed and manufactured. The geometries of the trial castings were designed according to the aim that residual distortion of the castings is ensured after cooling to ambient temperature. A stress lattice, and a V-shaped lid were designed to be cast in high-pressure die-casting to exhibit distortion due to their own geometry or in the latter case by a deliberately massive gating system. Different process parameters were tested in several trial casting series. The macroscopic distortion (and the global strain) of the castings were measured with means of tactile methods. The trial castings were produced from commonly used high-pressure die-casting alloys AlSi12(Fe) and AlSi10MnMg. For the alloy AlSi10MnMg thermo-physical and thermo-mechanical data were measured in order to obtain necessary data for numerical simulation. By time and temperature measurements during the trial castings, input parameters for numerical simulation were obtained. Numerical simulation models for the calculation of the occurring distortion were established. These calculation models only contained measured data respectively data which were derived from direct measurements. No unphysical fit parameters were used. The distortion values from experiments and simulations for both the stress lattice and the V-shaped lid are presented and were compared qualitatively and quantitatively to the established model predictions.
Translated title of the contributionMeasurement and Simulation of Distortion in High-Pressure Die-Castings
Original languageGerman
QualificationDr.mont.
Supervisors/Advisors
  • Ludwig, Andreas, Assessor B (internal)
  • Schumacher, Peter, Assessor A (internal)
Publication statusPublished - 2012

Bibliographical note

embargoed until null

Keywords

  • Simulation
  • High-Pressure Die-Casting
  • Distortion
  • Residual Stress
  • Aluminium
  • Ansys

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