Abstract :
The accurate prediction of die-casting performance is essential for the design of die-casting dies, the main purpose being to produce an accurate part, but the effecting factors in a good design are the decision of the mold-surface, the runner shape and operating conditions. In order to understand the practical conditions in die casting, this research studies the runner part and the die-body parts separately during the process of experiment. A die-casting and mold-milling test has been designed according to the experimental methods.
A finite element method was used to obtain the displacement and deformation from the measurement of the temperature in the cavity or by simulation in order to be able to find the optimum gate position of the design-mold. An abductive network for the modeling of the die casting and milling process, and the results of the finite element method, has been built. The abductive network is composed of a number of functional nodes. Once the die-casting parameters (the high-speed injection position, the runner injection angle, the runner sectional ratio, and gate position) or milling parameters (the spindle speed, the feed rate, and the milling angle) are given, the die-casting performance (the mold accuracy and the accuracy of the product part) can be predicted accurately by this developed network. A simulation annealing optimization algorithm with a performance index to obtain a perfect part can search for the optimal die-casting design parameters.
