Abstract
This article describes the influence of the high pressure diecasting process parameters as the geometry of the ingate area, the alloy injection parameters to the structural resistance of pinion housings, which are part of the steering systems.
The objective of this study is to ameliorate the health of the injected material in the mold, by reducing the shrinkage porosities which is part of the high pressure diecasting process.
The research is organised in two main steps: a preliminar one concerning the virtual simulation, and a second one which is related directly to the mold, with the objective to correlate the virtual simulations with the results obtained with the mould.
The virtual simulation has the objective to improve the design of the high pressure diecasting process especially the runner and overflow system, using special software for mold flow analysis and for solidification.
The filling of the molds cavities and the solidification of the alloy in the cavities are the main factors for the health of the material of the diecasted parts from point of view of porosity. The filling simulation supports the design of the runner and venting systems and allows to improve the mold from early design stage, in order to minimize the antrenation of gas porosities. The solidification simulation supports the design of the part from technological point of view and indicates the critical areas which may contain shrinkage porosities after solidification.
Keywords: High pressure die casting, aluminium, pinion housing, porosity, mold, squezze