Prediction and Verification of Distortion in Products Using Mold Cavity Temperature and Pressure During the High Pressure Die-Casting (HPDC) Process

초록

In response to the industrial demand for large-scale products, such as those required for the lightweight construction of electric vehicles, this paper addresses the significant challenge of distortion in high pressure die-casting (HPDC), particularly as it scales up to gigacasting. Recognizing the critical need to prevent these shape discrepancies in larger products, which are notably greater than those in smaller counterparts, we introduce a novel approach that utilizes data on mold internal temperatures and pressures to simulate the casting process and predict distortion. Our simulation method encompasses all factors that could influence product shape during production, including shrinkage due to solidification, pressure exerted during product ejection, and cooling to room temperature. To verify the predicted deformations, we employed a laser scanner to measure the shape errors in the actual products. The comparison between measured errors and those anticipated by our simulation demonstrated the ability to predict actual product shape deformation with remarkable accuracy. This research not only presents a significant advancement in predicting and thereby mitigating distortion in HPDC as it extends to gigacasting but also contributes to enhancing product quality and manufacturing efficiency in large-scale production environments. © American Foundry Society 2025.

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