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Roychowdhury_MSThesis.pdf (4.33 MB)

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Investigation of Flash-free Die Casting by Overflow Design Optimization

Roychowdhury, Sayak
http://orcid.org/0000-0003-4306-9334
http://rave.ohiolink.edu/etdc/view?acc_num=osu1406121850

Abstract Details

2014, Master of Science, Ohio State University, Industrial and Systems Engineering.
In die casting process, flash is a common problem caused by the impact pressure spike of the molten metal inside the die cavity. This can be attributed to the quick deceleration of the plunger when the cavity is full. Considerable waste of raw material, higher maintenance cost, low efficiency, high post processing cost are some of the adverse consequences of this phenomenon. The problem can be viewed from a design perspective, for instance, in SoftShot® technology the size of the overflows are designed to limit the pressure spike. In this research, this idea has been studied, using a hydraulic bench test and a mathematical optimization approach. The hydraulic bench test is set up to emulate the phenomenon of pressure spike caused by fluid flow. The pressure and the deceleration values are recorded for fluid flow through orifices of different size. In the second approach, a mathematical model for estimation of peak cavity pressure is optimized using Differential Evolution Algorithm and Nelder Mead Revised Simplex Search methods. Both of these methods indicate that the impact pressure can be minimized by implementing proper design of overflows.
Jerald Brevick (Committee Member)
Theodore Allen (Advisor)
80 p.
Industrial Engineering; Operations Research
Die Casting, Flash, Overflow, Hydraulic Bench Test, Optimization, Mathematical Model

Recommended Citations

Citations

  • Roychowdhury, S. (2014). Investigation of Flash-free Die Casting by Overflow Design Optimization [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1406121850

    APA Style (7th edition)

  • Roychowdhury, Sayak. Investigation of Flash-free Die Casting by Overflow Design Optimization. 2014. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1406121850.

    MLA Style (8th edition)

  • Roychowdhury, Sayak. "Investigation of Flash-free Die Casting by Overflow Design Optimization." Master's thesis, Ohio State University, 2014. http://rave.ohiolink.edu/etdc/view?acc_num=osu1406121850

    Chicago Manual of Style (17th edition)

osu1406121850
935
© 2014, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.