Enhancement and Analysis of Pressure Die Casting Method with Aluminum Alloy to Increase its Material Machinability and Workability by using Finite Volume Method

Mechanical Engineering

Present analysis is on fluent 15.0. It was carried out on considering A356 (molten aluminium) material with steel die. The study was conducted by using the Finite volume method. Reynolds stresses and wall shear stresses, has been analyzed by ANSYS 15.0. A simplified and idealized finite volume model by using symmetry assumption and a non-simplified finite volume model of process have been used in the analyses. The major study was done on pressure die casting by using different fillet radius and chamfer angle. In our analysis, ANSYS is used and the model is developed on UNIGRAPHICS 8.0 and also analysed for FLUENT 15.0. The analysis results show that 30 degree of chamfer angle and 6mm of fillet radius gives absolute convergence on pressure and temperature, Validation and optimization is done to determine the effect of pressure die casting process during working condition. The Reynolds stresses is analysed in pressure die casting for enhancement of machinability to reduce internal stresses generated due to imbalance of temperature and pressure. Wall shear stresses were also analysed at the die and molten metal interface zone for enhancement of workability for product and to reduce surface defects on manufactured product. Hence chamfer angle of 30 degree on die and fillet radius of 6mm shows minimum Reynolds stresses and wall shear stress with high temperature and pressure distribution on squeeze die casting process..

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