1.
N. Erhard
Oskar Frech GmbH + Co. KG, Schorndorf, Germany
FUTURE DEMANDS ON DIE CASTING AND TECHNICAL REQUIREMENTS FOR ITS PROFITABILITY

2.
R. Dańko
Faculty of Foundry Engineering, AGH University of Science and Technology, Krakow, Poland
THE STATE OF ART AND FORESIGHT OF WORLD CASTING PRODUCTION. THE ROLE OF THE FACULTY OF FOUNDRY ENGINEERING IN EDUCATING ENGINEERS FOR CASTING INDUSTRY.

3.
A.Mahmutović1, S. Kastelic1, 2, M. Petrič2, V. Buda3, P. Mrvar2
1 TC Livarstvo, Ljubljana, Slovenia
2 University of Ljubljana, Faculty of Natural Sciences and Engineering, Ljubljana, Slovenia
3 MAHLE Letrika Komen, Komen, Slovenia
HPDC TOOL AND PROCESS DESIGN USING FEM ANALYSIS

4.
T. Balaško, M. Petrič, J. Medved, P. Mrvar
Faculty of Natural Sciences and Engineering, University of Ljubljana, Ljubljana, Slovenia
THE INFLUENCE OF THERMAL CONDUCTIVITY FOR DIFFERENT MOULD MATERIALS ON SOLIDIFICATION OF AlSi9Cu3 ALLOY

1.
N. Erhard
Oskar Frech GmbH + Co. KG, Schorndorf, Germany
FUTURE DEMANDS ON DIE CASTING AND TECHNICAL REQUIREMENTS FOR ITS PROFITABILITY

Abstract

The previous examples have shown some instruments on how to improve the profitability of die casting by means of targeted innovations, but also by benchmark comparisons. Process data from which you can obtain reliable, objective information and which can then be used for the purpose-oriented improvements are helpful.

The technology for data-based information generation is available. In order to draw the right conclusions, there is generally also a need for understanding and knowledge in the various fields of die casting. In this respect, the Frech Group is set up in accordance with this in order to continually improve die casting together with our customers and to position it as a modern industry for the future through innovations and novelties.

Abstract

The casting production is considered as one of the main factors influencing the development of world economy. The state of art and foresight of world’s casting production is discussed in the paper on the basis of the latest statistical data. The progress gained during the last few years in foundry engineering is shown as a way to further development of foundry technology. The last decade brought significant changes in the world map of the greatest casting producers. Globalization and transformation of economic systems is reflected by variations of foundry production in different countries, more over the globalization of economy is regarded not only as a chance but also as a menace for the Polish and European foundries [1-5].

The second part of the presentation presents the development of foundry and metallurgical sciences at the AGH University of Science and Technology in Krakow, Poland, since the time when a Faculty of Iron and Steel Practice was established in 1922 until the present day. The study outlines the history of creating a scientific, didactic and organization profile of the Faculty of Foundry Engineering, founded by the most eminent members of AGH research staff who practice the disciplines related with iron steel and non-ferrous metals casting industry in a widely understood meaning of this word.

A short characteristic of the didactic activities of the faculty was given, and the areas of research and cooperation with industry were described. The role, which the faculty plays in the growth of the Polish casting industry, was emphasized.

Key words: foundry, casting, production, development, education

Abstract

Using numerical simulations in product development is today a standard way for most of the companies. Especially on the field of foundry the casting technology development for a part is based on the numerical simulations. In this article will be presented technology development for a casting. Using numerical simulations several gating systems were tested to achieve best possible melt flow and casting with acceptable casting defect. The simulation includes analysis of stresses and deformations in the casting and in the tool considering toll heating and cooling system. With numerical simulations complete casting process can be optimized to minimize problems when the production starts. Also, we can predict the problems that can be critical during the production lifetime.

Key words: HPDC, casting process design, FEM analysis, ProCAST

Abstract

The lifetime of pressure die casting moulds is progressively more important. Steels have the best price / lifetime ratio and are often used for production of die-casting moulds. Thermal conductivity and its effect on the solidification of castings are also increasingly important. Increased thermal conductivity shortens casting cycles and at the same time extends the lifespan of moulds. We decided to simulate high-pressure die casting of aluminium alloy 226 (AlSi9Cu3). The simulation was carried out in ProCAST software tool, the casting geometry and the casting system were created in the SOLIDWORKS software tool. In particular, we were interested in how different values of thermal conductivity of permanent moulds (dies) influence solidification and cooling of the cast. Therefore, the purpose was to make simulations of the same castings where we changed the permanent mould materials, which had different thermal conductivity, density and other material properties. We used the following materials for moulds: hot work tool steels – H-13, Dievar, HTCS-130, DAC-MAGIC and W350, maraging steel – MARVAL18 and alloys with increased thermal conductivity – CuAg12, Allper52 and Ni75Al. The last three alloys were chosen primarily for theoretical study of the influence of increased thermal conductivity on the solidification, namely, the prices of such moulds would most likely be too high in comparison with the moulds that are most frequently used in the industry. The results showed that the thermal conductivity affects the solidification, which is also evident from the temperature gradients of the moulds and the cooling speed of the individual cast.

Key words: High-pressure die casting, hot work tool steels, thermal conductivity, Al-foundry alloy.