Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Kód výsledku v IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F68407700%3A21220%2F23%3A00365208" target="_blank" >RIV/68407700:21220/23:00365208 - isvavai.cz</a>

Výsledek na webu

<a href="https://doi.org/10.1089/3dp.2022.0225" target="_blank" >https://doi.org/10.1089/3dp.2022.0225</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.1089/3dp.2022.0225" target="_blank" >10.1089/3dp.2022.0225</a>

Jazyk výsledku

angličtina

Název v původním jazyce

Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Popis výsledku v původním jazyce

Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (~270 x 270 x 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the ŠKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in ŠKODA AUTO production also decreased.

Název v anglickém jazyce

Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Popis výsledku anglicky

Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (~270 x 270 x 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the ŠKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in ŠKODA AUTO production also decreased.

Druh

J_imp - Článek v periodiku v databázi Web of Science

CEP obor

—

OECD FORD obor

20301 - Mechanical engineering

Projekt

—

Návaznosti

S - Specificky vyzkum na vysokych skolach

Rok uplatnění

2023

Kód důvěrnosti údajů

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů

Název periodika

3D Printing and Additive Manufacturing

ISSN

2329-7662

e-ISSN

2329-7670

Svazek periodika

10

Číslo periodika v rámci svazku

4

Stát vydavatele periodika

US - Spojené státy americké

Počet stran výsledku

22

Strana od-do

587-608

Kód UT WoS článku

000953508500001

EID výsledku v databázi Scopus

2-s2.0-85169002624