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Simulation Validation and Redesign of a Die Casting Mold
A local control of the heat balance in die casting tools enables robust processing, faster cycle times as well as longer die lifetimes. With new manufacturing capabilities such as Additive Manufacturing (AM), engineers have almost unlimited possibilities to design cooling structures. To facilitate a
Keywords: simulation, 3D-printing, cad, cae
A local control of the heat balance in die casting tools enables robust processing, faster cycle times as well as longer die lifetimes. With new manufacturing capabilities such as Additive Manufacturing (AM), engineers have almost unlimited possibilities to design cooling structures. To facilitate and fully use to potential of AM technologies, ETH and Bühler are developing an algorithm that automatically synthesizes and optimizes cooling channels based on the part geometry.
The new tool for the Bühler lab has been equipped with conventional cooling channels and multiple thermal probes. The objective of this work is to validate the thermal simulation used and in a second step to redesign the inserts of this tool using the design freedom available with metal 3D printing. The so-far developed methods should be used and their effectiveness assessed. The resulting design should minimize the cycle time and overcome the need for spraying coolant directly on the surface.
A local control of the heat balance in die casting tools enables robust processing, faster cycle times as well as longer die lifetimes. With new manufacturing capabilities such as Additive Manufacturing (AM), engineers have almost unlimited possibilities to design cooling structures. To facilitate and fully use to potential of AM technologies, ETH and Bühler are developing an algorithm that automatically synthesizes and optimizes cooling channels based on the part geometry. The new tool for the Bühler lab has been equipped with conventional cooling channels and multiple thermal probes. The objective of this work is to validate the thermal simulation used and in a second step to redesign the inserts of this tool using the design freedom available with metal 3D printing. The so-far developed methods should be used and their effectiveness assessed. The resulting design should minimize the cycle time and overcome the need for spraying coolant directly on the surface.
1. Analyse the current tool design with cycle simulation (filling, solidification, spraying).
2. Validation of the simulation results with thermal measurements
3. Make design propositions for new conformal cooled inserts by changing the segmentation based on the results of current optimization methods (Point Cloud, ML augmented algorithm).
4. Critically assess the current design methodology and implement improvements based on the results of the comparison.
5. Analyse and compare the new designs with the original
1. Analyse the current tool design with cycle simulation (filling, solidification, spraying). 2. Validation of the simulation results with thermal measurements 3. Make design propositions for new conformal cooled inserts by changing the segmentation based on the results of current optimization methods (Point Cloud, ML augmented algorithm). 4. Critically assess the current design methodology and implement improvements based on the results of the comparison. 5. Analyse and compare the new designs with the original