| Title |
Evaluation of Cooling Performance of an Additive Manufactured Gravity Die Casting Mold with Conformal Cooling Channel |
| Authors |
박유진(Yu Jin Park); 김억수(Eok Soo Kim); 이정훈(Jeong Hun Lee); 최지환(Ji Hwan Choi); 윤필환(Pil Hwan Yoon); 강호정(Ho Jeong Kang); 김동현(Dong Hyun Kim); 박용호(Yong Ho Park); 고종완(Jong Wan Ko) |
| DOI |
https://doi.org/10.3365/KJMM.2021.59.9.652 |
| ISSN |
1738-8228(ISSN), 2288-8241(eISSN) |
| Keywords |
conformal cooling channel; additive manufacturing; casting simulation; Al-Si-Cu alloy casting; secondary dendrite arm spacing |
| Abstract |
A cooling channel with an optimized design provides not only high throughput with gravity die casting, but also guarantees product quality. A conformal cooling channel (CC) whose structure follows the shapes or surfaces of the mold cavity has attracted great attention in the die casting industry, because it allows rapid and uniform cooling. However, implementing conformal cooling remains highly challenging, because the complicated geometries of CC are difficult to form using conventional fabrication methods such as drilling and milling. In recent years, advances in additive manufacturing (AM) technology have made it possible to fabricate products with complex and elaborate structures. In this paper, a gravity die casting mold with CC was designed and built using AM technology. The cooling channel performance was estimated and evaluated using an Al-Si-Cu alloy casting simulation and die casting experiments, respectively. The casting simulation results showed that the cooling performance of the CC was enhanced by ca. 10% compared with that of a conventional cooling channel. The experimental cooling performance of the CC improved by ca. 8% compared to that of a conventional cooling channel, and the increment in performance was consistent with the simulation results. In addition, microstructural evidence clarified that the effective cooling performance of CC could be attributed to the decrement (ca. 17%) of the secondary dendrite arm spacing (SDAS) of the Al-Si-Cu alloy. In this research, AM technology provides a novel way to fabricate functionally superior CC molds that are hardly producible with traditional methods.(Received May 14, 2021; Accepted June 4, 2021) |