lost core neue perspektiven im druckguss dario pierri buhler ag
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Lost Core - neuePerspektiven imDruckguss
Dario Pierri,
Bhler AG
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Introduction to Lost Core Technology.
Basic Idea of Lost Core Technology.
Using lost cores in the HPDC process to create undercuts orfluid ducts.
Integrating additional functions inHPDC parts.
Reducing machining, sealing and assembling.
INNOVATIVE TECHNICAL SOLUTIONS WITH LOST CORE TECHNOLOGY.
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Introduction to Lost Core Technology.
Overview of Different Lost Core Technologies.
Lost Core Technologies
OtherTechnologies
Melt
OutGas
InjectionTubes
Sand Cores
Inorganic Organic Croning
Salt Core Technologies
Solid Phase
PressedShotBlast
Liquid Phase
Semi-solid
100%Liquid
Coatings
Sintered or notSintered
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Introduction to Lost Core Technology.
Properties of Salt Core Technology.
ADVANTAGES
No use of chemicalbinders. No use of coating. No use of toxic salts.
CHALLENGES
Ceramic behavior (brittle). Needs to be demolded for
HPDC process. Limited in volume
dimensions.
PROPERTIES
Smooth surface quality. High resistance to heat. Water soluble. Thermal insulator.
Volkswagen AG BOCAR3D-Freiformflchen Projekt
EXAMPLES
3D-Free-form Surfaces Project Volkswagen AG Bhler AG
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Salt Core Simulation.
Material properties of salt mixture.
salt core specimen
Material property Solid Liquid
Solidustemperature - ca. 640C
Liquidustemperature - ca. 690C
Density 2.3 2.5 kg/dm3 1.7 1.9 kg/dm3
Specific heat 1.0 1.4 kJ/kg*K 1.6 1.9 kJ/kg*K
Thermal conductivity 2 - 4 W/m*K 1 - 2 W/m*K
Latent heat of fusion - ~ 400 kJ/kg
Thermal expansion 4e-05 6e-05 K-1 -
Viscosity - 1 - 2 mPas
Youngs Modulus > 10000 N/mm2 -
Poisson ratio 0.18 0.24 -
Avg. bending strength > 18 MPa -
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Possibilities of simulation.
Simulation with materials salt and aluminum.
Aluminum Casting
Design of gating andventing system Check of flow circulationaround salt core
FSI Simulation
Fluid-Structure-Interaction:Calculation of forces affectingthe salt core during fillingprocess
Salt Core Production
Design of gating andventing system (salt die) Pre-check of shot profile Check of solidification
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Aluminum Simulation.
Results of FSI Simulation.
Prediction of stresses on coresurface by using Fluid Structure
Interaction Simulation.
Comparison of impact due todifferent ingate velocities.
Finite Elements Method - Mesh (FEM)
Velocity 1~ 40 m/s
Velocity 2~ 80 m/s
Velocity 3~ 120 m/s
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Part and Die Design for Lost Core Technology.
Salt core
Research of Shrinkage behavior.
Part design of salt core.
Die design for salt core production
Gating system design for salt core.
Thermo balance of the salt core die.
Salt core positioning before aluminum casting
New design ideas for HPDC partsHPDC die; Symposium sample
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Process steps.
Overview of production chain.
Insert Salt
Core
DosingMixing
Melting
Stock / Quality
Salt stockSalt Casting
Salt Core
removal /
recyclingQualitycheck
AluminiumCasting
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Salt Casting
DosingMixing
MeltingSalt stock
Salt Core
removal /
recyclingQualitycheck
Insert Salt
Core
AluminiumCasting
Stock / Quality
Process steps.
Salt core casting out of liquid phase
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Process steps.
Salt core casting out of liquid phase - Movie
Movie
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Salt Core
inlay
Stock / Quality
Salt Casting
Salt Core
removal /
recyclingQualitycheck
AluminumCasting
DosingMixing
MeltingSalt stock
Process steps.
Aluminum casting with salt core inlay.
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The correct support of the salt core in the die is relevant know-how.
FSISimulation optimises the second phase (filling phase).
Shot is real-time controlled. This is very important in order to avoid
the breaking of the inserted salt core and to guarantee ahigh
reproducibiltiy of the shot.
Process steps.
Aluminum casting with salt core inlay.
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DosingMixing
MeltingSalt stock
Salt Core
inlay
AluminiumCasting
Salt Core
removal /
recyclingQualitycheck
Salt Casting
Stock / Quality
Process steps.
Removing of salt core
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100% removing of salt.
No damage of the aluminum part.
Low cycle time.
Energy and resource saving.
Requirements for a core-removing unit:
Cut through the aluminium part after removing the salt core
Process steps.
Removing of salt core
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Different geometries of salt cores
are removable with water-jet:
blind hole.
curved channels.
Examples for removed cores.
Process steps.
Removing of salt core
Process values:
Removal time 90 sec
Water consumption 30 - 40 l
Water pressure max. 600 bar
Water temperature 20C
Values for 3-cylinder engine block:
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Salt water
Only a little percentage of salt is
dissolved during the removingprocess. Salt content in waterafter removing
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Melting&DosingMixing Salt Core Casting Aluminium Casting Core Removing
Ladleror
dosing furnace
Summary.
Process chain and necessary machines for Lost Core production.
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Thank you.
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Backup
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Why is Bhler developping Lost Core technology?
Existing processes (e.g. Mercury Marine, Yamaha)
were developed only for their own needs.
At the moment there isnt an equipment
manufacturer that is able to provide a
complete solution for industrial process
with high efficiency.
Bhlers focus is to provide the necessary
equipment for the Lost Core technology that
is suitable forindustrial process with high efficiency.
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Patents
With our patents we protect the process and the mixture in order to
guarantee the freedom to operate of our customers.
Patent on process for salt core production
Patent on salt mixture
Patent on removal process
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Aluminum Simulation.
Results of FSI Simulation.
Ingate velocity has an influence on core viability.
Intensification pressure may not be applied before the cavity is filled completely.
0
20
40
60
80
100
120
140
0.00E+00
5.00E+06
1.00E+07
1.50E+07
2.00E+07
2.50E+07
3.00E+07
3.50E+07
4.00E+07
4.50E+07
5.00E+07
2.170 2.180 2.190 2.200 2.210 2.220
IngateVelocity[m/s]
MeanIsoStress[Pa]
Filling Time t [s]
Mean Iso Stress @ 0.7 m/s
Mean Iso Stress @ 1.4 m/s
Mean Iso Stress @ 2.1 m/s
Ingate Velocity @ 0.7 m/s
Ingate Velocity @ 1.4 m/s
Ingate Velocity @ 2.1 m/s
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Calculation for cost effectiveness.
Example for cost calculation
Formkosten pro Salzkern 0.41 EUR
Giesskosten pro Salzkern 1.20 EUR
Material- und Schmelzkosten pro Salzkern 0.49 EURKosten pro Salzkern 2.10 EUR
1. Casting of salt cores
2. Overcasting with aluminium
Cost calculation done by the customer. Comparable to standard DC with inserts.
3. Core removing
Werkzeugkosten pro Salzkern 0.18 EUR
Entkernungskosten pro Salzkern 0.71 EURWasserverbrauchkosten pro Kern 0.11 EUR
Sondermll Entsorgungskosten pro Kern (0.7kg) 0.22 EUR
Kosten pro Entkernung 1.22 EUR
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Calculation for cost effectiveness.
To ensure market penetration the salt core technology has to have
lower process costs than alternative process (e.g. gravity casting with
sand cores).
We calculated the process costs of different parts. The cost
effectiveness is promising.
Water outlet in gravity casting with sand core Water outlet in HPDC with salt core
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Technology substitut ions or fully new parts.
permanent mold.
sand casting.
Process substitutionApplication on
existing technologiesNew parts
Lost Core
low pressuredie casting.
permanent mold.
injection molding.
Vision.
FHNW Giessereitag 2013
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