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Fundamentals of Die Casting Design.pdf

November 7, 2009 · Filed Under Mechanical & Industrial Engineering  · Tags: , , , ,

Taken from Introduction: This book, “Fundamentals of Die Casting Design,” describes the fundamentals of die casting process design and economics for engineers and others. This book is designed to fill the gap and the missing book on economy and scientific principles of die casting. It is hoped that the book could be used as a reference book for people who have at least some basics knowledge of science areas such as calculus, physics, etc.

It has to realized the some material is very advance and required knowledge of fluid mechanics particularly compressible flow and open channel flow. This author’s popular book on compressible flow should provide the introductory in that area. The readers’ reactions to this book and the usage of the book as a textbook suggested that the chapter which deals with economy should be expand. In the following versions this area will strength and expended.

The structure of this book is such that many of the chapters could be usable independently. For example, if you need information about, say, economy of the large scale productions, you can read just chapter (12). I hope this makes the book easier to use as a reference manual. However, this manuscript is first and foremost a textbook, and secondly a reference manual only as a lucky coincidence.

I have tried to describe why the theories are the way they are, rather than just listing “seven easy steps” for each task. This means that a lot of information is presented which is not necessary for everyone. These explanations have been marked as such and can be skipped. Reading everything will, naturally, increase your understanding of the many aspects of fluid mechanics.

Contents:

  • 1 Introduction
    • The importance of reducing production costs
    • Designed/Undesigned Scrap/Cost
    • Linking the Production Cost to the Product Design
    • Historical Background
    • Numerical Simulations
    • “Integral” Models
    • Summary
  • 2 Basic Fluid Mechanics
    • Introduction
    • What is fluid? Shear stress
    • Thermodynamics and mechanics concepts
  • 3 Dimensional Analysis
    • Introduction
    • The Die Casting Process Stages
    • Special Topics
    • Estimates of the time scales in die casting
    • Similarity applied to Die cavity
    • Summary of dimensionless numbers
    • Summary
    • Questions
  • 4 Fundamentals of Pipe Flow
    • Introduction
    • Universality of the loss coefficients
    • A simple flow in a straight conduit
    • Typical Components in the Runner andVent Systems
    • Putting it all to Together
  • 5 Flow in Open Channels
    • Introduction
    • Typical diagrams
    • Hydraulic Jump
  • 6 Runner Design
    • Introduction
  • 7 pQ2 Diagram Calculations
    • Introduction
    • The “common” pQ2 diagram
    • The validity of the “common” diagram
    • The reformed pQ2 diagram
    • Design Process
    • The Intensification Consideration
    • Summary
    • Questions
  • 8 Critical Slow Plunger Velocity
    • Introduction
    • The “common” models
    • The validity of the “common” models
    • The Reformed Model
    • Summary
    • Questions
  • 9 Venting System Design
    • Introduction
    • The “common” models
    • General Discussion
    • The Analysis
    • Results and Discussion
    • Summary
    • Questions
  • 10 Density change effects
  • 11 Clamping Force Calculations
  • 12 Analysis of Die Casting Economy
    • Introduction
    • The “common” model, Miller’s approach
    • The validity of Miller’s price model
    • The combined Cost of the Controlled Components
    • Die Casting Machine Capital Costs
    • Operational Cost of the Die Casting Machine
    • Runner Cost (Scrap Cost)
    • Start–up and Mold Manufacturing Cost
    • Personnel Cost
    • Uncontrolled components
    • Summary
    • Question
  • A Fanno Flow
    • Introduction
    • Fanno Model
    • Non–Dimensionalization of the Equations
    • The Mechanics and Why the Flow is Choked?
    • The Working Equations
    • Examples of Fanno Flow
    • Supersonic Branch
    • Maximum Length for the Supersonic Flow
    • Working Conditions
    • Practical Examples for Subsonic Flow
    • The Approximation of the Fanno Flow by Isothermal Flow
    • More Examples of Fanno Flow
    • The Table for Fanno Flow
    • Appendix – Reynolds Number Effects
  • B What The Establishment’s Scientists Say
    • Summary of Referee positions
    • Referee 1 (from hand written notes)
    • Referee 2
    • Referee 3
  • C My Relationship with Die Casting
  • Establishment
  • Bibliography
  • Index
  • Subjects index
  • Authors index

List of figures:

  • The profits as a function of the amount of the scrap
  • Increase of profits as reduction of scrap reduction
  • The velocity distribution in Couette flow
  • The deformation of fluid due to shear stress as progression of time
  • A very slow moving piston in a still gas
  • Stationary sound wave and gas moves relative to the pulse
  • Gas flow through a converging–diverging nozzle
  • The stagnation properties as a function of the Mach number, k=1.4
  • Various ratios as a function of Mach number for isothermal Nozzle
  • Rod into the hole example
  • Hydraulic jump in the shot sleeve
  • Filling of the shot sleeve
  • Heat transfer processes in the shot sleeve
  • Solidification of the shot sleeve time estimates
  • Entrance of liquid metal to the runner
  • Flow in runner when during pressurizing process
  • Typical flow pattern in die casting, jet entering into empty cavity
  • Transition to turbulent flow in instantaneous flow after Wygnanski
  • Flow pattern in the shot sleeve
  • Two streams of fluids into a medium
  • Schematic of heat transfer processes in the die
  • The oscillating manometer for the example 3.1
  • Mass Balance on the lest side of the manometer
  • Rigid body brought into rest
  • The results for the flow in a pipe with orifice
  • General simple conduit description
  • General simple conduit description
  • A sketch of the bend in die casting
  • A parallel connection
  • Equilibrium of Forces in an open channel
  • Specific Energy and momentum Curves
  • A geometry of runner connection
  • y connection
  • Schematic of typical die casting machine
  • A typical trace on a cold chamber machine
  • pQ2 diagram typical characteristics
  • ¯ P as A3 to be relocated
  • Presure of die casting machine
  • P1 as a function of Pmax
  • KF as a function of gate area, A3
  • Die casting characteristics
  • Various die casting machine performances
  • Reduced pressure performances as a function of Ozer number
  • Schematic of the plunger and piston balance forces
  • Metal pressure at the plunger tip
  • Hydralic piston schematic
  • The gate velocity, U3 as a function of the plunger area, A1
  • The reduced power as a function of the normalized flow rate
  • A schematic of wave formation in stationary coordinates
  • The two kinds in the sleeve
  • A schematic of the wave with moving coordinates
  • The Froude number as a function of the relative height
  • The relative shrinkage porosity as a function of the casting thickness
  • A simplified model for the venting system
  • The pressure ratios for air and vacuum venting at end
  • The control volume of the phase change
  • Production cost as a function of the runner hydraulic diameter
  • The reduced power as a function of the normalized flow rate
  • Control volume of the gas flow in a constant cross section
  • Various parameters in Fanno flow as a function of Mach number
  • Schematic of Example (A.1)
  • The schematic of Example (A.2)
  • The maximum length as a function of specific heat, k
  • The effects of increase of 4fL
  • D on the Fanno line
  • The development properties in of converging nozzle
  • Min and m? as a function of the 4fL D
  • M1 as a function M2 for various 4fL D
  • M1 as a function M2
  • The pressure distribution as a function of 4fL
  • D for a short 4fL D
  • The pressure distribution as a function of 4fL
  • D for a long 4fL D
  • The effects of pressure variations on Mach number profile
  • Mach number as a function of 4fL
  • D when the total 4fL D = 0.3
  • Schematic of a “long” tube in supersonic branch
  • The extra tube length as a function of the shock location
  • The maximum entrance Mach number as a function of 4fL D
  • Unchoked flow showing the hypothetical “full” tube
  • The results of the algorithm showing the conversion rate
  • Solution to a missing diameter
  • M1 as a function of 4fL
  • D comparison with Isothermal Flow
  • “Moody” diagram

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