The entire process for manufacturing tied up space, as well as labour, The first iterations of the DecaEdge™ design required fabrication from three separately cast parts, each two meters in length. CR is the only manufacturer in the world to offer a range of cast lips for large mining wheel loaders. In 2016, CR designed the DecaEdge™ cast lip, which was designed to fit large mining wheel loaders. Patternmaking, mouldmaking and tooling & Rapid Prototyping, rapid tooling & 3D Printing.Discharging, Decoring, Fettling, Finishing.The variation of spraying, in turn has shown that intermittent spraying of smaller amounts causes smaller tensile stresses in the die surface than one single, intense spray stroke. Likewise, the temperature gradient during filling/solidification is also reduced due to the colder melt. This results in a smaller thermal shock during spraying. This can be explained as follows: Reducing the casting temperature leads to a reduction of the average die temperature. Reducing the pouring temperature minimizes both the tensile stresses during spraying and the compressive stresses during filling/solidification, thus increasing the tool life. Overall, the stress range decreases with lower cooling agent temperature (see Figure 5). The temperature increase of the die surface during filling/solidification, however, remains approximately the same, which means that the level of compressive stresses is also almost identical. This, in turn, leads to a reduced thermal shock during spraying and, thus, to lower tensile stresses. This effect can be explained by the fact that the die is on average colder with colder cooling agents. The temperature of the cooling medium has a considerable influence on the tool life. Explanation: The average die temperature does not change, resulting in the maximum stresses both during spraying and during filling/solidification not changing either. In the area analyzed, the diameter of the cooling channels has no influence on the tool life. These led to the following fundamental insights: To minimize the simulation effort, a substitute geometry was used that had characteristics similar to the original casting, see Figure 1.įor the other process variables, corresponding virtual Designs of Experiments were conducted, too. The foundry used MAGMASOFT ® and MAGMAdielife to estimate the die life for their process. Temperature of the temperature control mediumįor each of the five parameters, a separate systematic set-up using the in-build Design of Experiment was done.Diameters of the temperature control channels.Distance between temperature control channels and die surface.Mazzucconi decided to investigate the following parameters: These stresses are caused by temperature changes during the casting cycle. One of the major influencing factors on tool life are thermo-mechanical stresses in the die surface and the associated die erosion. Therefore, the aim of the project was to identify the main influencing factors on tool life in the process and adjust the casting process accordingly. Changes to the casting geometry were not an option due to the existing design freeze. Unfortunately, the die of a cast part that had been produced for a long time fell short of the expected tool life. The Italian foundry Mazzucconi used the capabilities of virtual Design of Experiments in MAGMASOFT ® to substantially increase the die life for a steering housing. Tool life is one of the main cost factors in high pressure die casting.
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