Title: Performance of a real-time local thermal management system for casting dies with multiple cooling channels

Authors: Tiebao Yang, Henry Hu, Xiang Chen, Yeou-li Chu, Patrick Cheng

Addresses: Department of Mechanical, Automotive & Materials Engineering, University of Windsor, Windsor, Ontario N9B 3P4, Canada. ' Department of Mechanical, Automotive & Materials Engineering, University of Windsor, Windsor, Ontario N9B 3P4, Canada. ' Department of Mechanical, Automotive & Materials Engineering, University of Windsor, Windsor, Ontario N9B 3P4, Canada. ' Department of Research and Development, Ryobi Die Casting (USA) Inc., Shelbyville, IN 46176–9720, USA. ' Department of Research and Development, Ryobi Die Casting (USA) Inc., Shelbyville, IN 46176–9720, USA

Abstract: In high-pressure die casting processes, proper control of die temperature is essential for producing superior quality components and yielding high production rates. Very often it is impractical to control die temperature to a specific point during solidification stages. In this paper, a computerised Intelligent Real-Time Monitoring and Control System (IRMCS) is developed for die casting processes involving cooling of a die with multiple channels. A local temperature controller is designed to confine temperature fluctuations of a die within a desirable range. The performance of the system is evaluated through a laboratory die casting process simulator in terms of measurement accuracy, time delay and local heat removal rate. The experimental results indicate that the developed control system is capable of adjusting the desirable supply of cooling water into multiple cooling lines. Hence, the ideal thermal pattern of the die becomes achievable.

Keywords: high-pressure die casting; temperature control; data acquisition; computer applications; local thermal management; casting dies; multiple cooling channels; real-time control; intelligent monitoring; real-time monitoring; intelligent control; process simulation; measurement accuracy; time delay; local heat removal.

DOI: 10.1504/IJMR.2007.013427

International Journal of Manufacturing Research, 2007 Vol.2 No.1, pp.74 - 87

Published online: 27 Apr 2007 *

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