Aluminum Wheel
Removal of the Defects in Aluminum alloy wheel is one of the more exacting tasks for engineers and metal casters.
SUTCAST serves as a useful tool to identify the component of the defects and porosity formation. It provides the distribution of the defects, locations of macro defects and identifies micro defects
| Part name: Al Wheel
Material: AL-A 356
Casting Process: (L.P.D.C) Low pressure die casting
Mold Material: H13 Steel
Weight: 9.2kg | The ultimate results of Case study presented here are: - Reduction of lead time and avoiding casting process design by try and error
- Increasing cast part production speed by a factor of over 2
- Shrinkage removal
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Initial Design Improved Design
Fluid Flow Filling |
 |  |
Shrinkage No Shrinkage
Filling sequences and thermal distribution in improved design Incomplete filling (time= 0.42 Sec)
after modifications on initial condition
Solidification simulation of initial design showed macro shrinkage defects in location and size, precisely in agreement with real cast wheel.
In order to remove macro shrinkage and to decrease the solidification time, mold design
1-Application of padding for improvement of directional solidification guaranteed by modeling
2-Inserting water cooled copper chill
3-Adjusting the temperature distribution of different die parts
4-Die heat transfer control with applying different coating thicknesses
The aluminum foundry industry has to focus on the quality and reliability of the products.
To produce good quality aluminum cast wheels, defects must be minimized and the quality of each production step must be controlled .
Modeling provides engineers with a way to understand the process dynamics and evaluate the quantitative effects of various process variables on the quality of the resulting products.