Conformal cooling as a support tool for eliminating local defects in high-pressure die casting series production

Kód výsledku v IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F68407700%3A21220%2F25%3A00376154" target="_blank" >RIV/68407700:21220/25:00376154 - isvavai.cz</a>

Výsledek na webu

<a href="https://doi.org/10.1007/s40964-024-00721-x" target="_blank" >https://doi.org/10.1007/s40964-024-00721-x</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.1007/s40964-024-00721-x" target="_blank" >10.1007/s40964-024-00721-x</a>

Jazyk výsledku

angličtina

Název v původním jazyce

Conformal cooling as a support tool for eliminating local defects in high-pressure die casting series production

Popis výsledku v původním jazyce

This study addresses a critical issue in mass-producing gearbox housing MQ200GA at Škoda Auto a.s. The combination of SW ProCAST simulations and metal 3D printing (laser powder bed fusion—L-PBF) overcomes challenges posed by full mold printing. Instead, the authors adapt the conformal cooling design, introducing specific channel paths in 3D printed inserts. Exploring conformal cooling (CC) and conformal cooling channels (CCC), the study focuses on stabilizing the temperature field, optimizing heat exchange, and improving part quality. Real production implementation successfully eliminates shrinkage porosity, demonstrated in a test series of 8 000 castings. Challenges with the unregulated cooling circuit temperature are acknowledged, along with a close correlation between simulations and real-world measurements. The feasibility of 3D-printed inserts in molds is confirmed in active production, producing over 43 000 castings. This experiment showcases the benefits of metal 3D printing in high-pressure die casting (HPDC). Despite challenges, the authors successfully modified serial tools for aluminum HPDC, deploying test 3D-printed inserts with CC directly into real production. This risk pays off, providing valuable insights for researchers and industry experts considering a similar approach.

Název v anglickém jazyce

Conformal cooling as a support tool for eliminating local defects in high-pressure die casting series production

Popis výsledku anglicky

This study addresses a critical issue in mass-producing gearbox housing MQ200GA at Škoda Auto a.s. The combination of SW ProCAST simulations and metal 3D printing (laser powder bed fusion—L-PBF) overcomes challenges posed by full mold printing. Instead, the authors adapt the conformal cooling design, introducing specific channel paths in 3D printed inserts. Exploring conformal cooling (CC) and conformal cooling channels (CCC), the study focuses on stabilizing the temperature field, optimizing heat exchange, and improving part quality. Real production implementation successfully eliminates shrinkage porosity, demonstrated in a test series of 8 000 castings. Challenges with the unregulated cooling circuit temperature are acknowledged, along with a close correlation between simulations and real-world measurements. The feasibility of 3D-printed inserts in molds is confirmed in active production, producing over 43 000 castings. This experiment showcases the benefits of metal 3D printing in high-pressure die casting (HPDC). Despite challenges, the authors successfully modified serial tools for aluminum HPDC, deploying test 3D-printed inserts with CC directly into real production. This risk pays off, providing valuable insights for researchers and industry experts considering a similar approach.

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

2025

Kód důvěrnosti údajů

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

Název periodika

Progress in Additive Manufacturing

ISSN

2363-9512

e-ISSN

2363-9520

Svazek periodika

10

Číslo periodika v rámci svazku

2

Stát vydavatele periodika

GB - Spojené království Velké Británie a Severního Irska

Počet stran výsledku

18

Strana od-do

1511-1528

Kód UT WoS článku

001271755700002

EID výsledku v databázi Scopus

2-s2.0-85198852343