Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor
The integrated die-casting rear floor (IDCRF) is a key technology for achieving lightweight, high-efficiency manufacturing in new energy vehicles. In this study, ProCAST was used to simulate the IDCRF forming process. Initial results revealed issues with delayed and asymmetric filling, leading to si...
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Elsevier
2025-06-01
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| Series: | Results in Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123025014690 |
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| author | Jian Dong Jufu Jiang Ying Wang Tianxiang Qin Minjie Huang Jingbo Cui Xiaodong Zhang Lingbo Kong Junliang Chen |
| author_facet | Jian Dong Jufu Jiang Ying Wang Tianxiang Qin Minjie Huang Jingbo Cui Xiaodong Zhang Lingbo Kong Junliang Chen |
| author_sort | Jian Dong |
| collection | DOAJ |
| description | The integrated die-casting rear floor (IDCRF) is a key technology for achieving lightweight, high-efficiency manufacturing in new energy vehicles. In this study, ProCAST was used to simulate the IDCRF forming process. Initial results revealed issues with delayed and asymmetric filling, leading to significant shrinkage porosity. Optimization of the gating system reduced the shrinkage volume from 368 cm3 to 270 cm3, achieving a 26.6 % decrease. To further minimize defects, a response surface methodology (RSM) was employed to analyze the effects of key process parameters. The results showed that pouring temperature had the greatest influence on shrinkage porosity, followed by mold temperature, fast injection speed, and slow injection speed. The optimal parameters determined by the RSM were: 693.5 °C pouring temperature, 186.7 °C mold temperature, 5.0 m s-1 fast injection speed, and 0.40 m s-1 slow injection speed. Under these conditions, the shrinkage porosity volume was further reduced by 59.1 %, and simulation results closely matched predictions. Mechanical testing of castings formed under optimal conditions showed excellent properties near the injection chamber, with a yield strength of 130.1 ± 4.6 MPa, ultimate tensile strength of 266.2 ± 1.9 MPa, and elongation of 11.1 ± 0.51 %. These findings demonstrate a robust simulation-based optimization strategy for improving quality and performance in large-scale integrated aluminum alloy die casting. |
| format | Article |
| id | doaj-art-e32ab0b1378849fb838c74a3f598dc80 |
| institution | OA Journals |
| issn | 2590-1230 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
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| series | Results in Engineering |
| spelling | doaj-art-e32ab0b1378849fb838c74a3f598dc802025-08-20T02:26:56ZengElsevierResults in Engineering2590-12302025-06-012610539910.1016/j.rineng.2025.105399Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floorJian Dong0Jufu Jiang1Ying Wang2Tianxiang Qin3Minjie Huang4Jingbo Cui5Xiaodong Zhang6Lingbo Kong7Junliang Chen8National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaNational Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR China; Corresponding author at: School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR China.School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, PR China; School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, PR China.National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaNational Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaNational Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaNational Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaNational Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaNational Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology Harbin 150001, PR China; School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, PR ChinaThe integrated die-casting rear floor (IDCRF) is a key technology for achieving lightweight, high-efficiency manufacturing in new energy vehicles. In this study, ProCAST was used to simulate the IDCRF forming process. Initial results revealed issues with delayed and asymmetric filling, leading to significant shrinkage porosity. Optimization of the gating system reduced the shrinkage volume from 368 cm3 to 270 cm3, achieving a 26.6 % decrease. To further minimize defects, a response surface methodology (RSM) was employed to analyze the effects of key process parameters. The results showed that pouring temperature had the greatest influence on shrinkage porosity, followed by mold temperature, fast injection speed, and slow injection speed. The optimal parameters determined by the RSM were: 693.5 °C pouring temperature, 186.7 °C mold temperature, 5.0 m s-1 fast injection speed, and 0.40 m s-1 slow injection speed. Under these conditions, the shrinkage porosity volume was further reduced by 59.1 %, and simulation results closely matched predictions. Mechanical testing of castings formed under optimal conditions showed excellent properties near the injection chamber, with a yield strength of 130.1 ± 4.6 MPa, ultimate tensile strength of 266.2 ± 1.9 MPa, and elongation of 11.1 ± 0.51 %. These findings demonstrate a robust simulation-based optimization strategy for improving quality and performance in large-scale integrated aluminum alloy die casting.http://www.sciencedirect.com/science/article/pii/S2590123025014690Integrated rear floorNumerical simulationIntegrated die-castingShrinkage and porosityMechanical properties |
| spellingShingle | Jian Dong Jufu Jiang Ying Wang Tianxiang Qin Minjie Huang Jingbo Cui Xiaodong Zhang Lingbo Kong Junliang Chen Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor Results in Engineering Integrated rear floor Numerical simulation Integrated die-casting Shrinkage and porosity Mechanical properties |
| title | Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor |
| title_full | Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor |
| title_fullStr | Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor |
| title_full_unstemmed | Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor |
| title_short | Research on numerical simulation and integrated die casting process of large complex thin-walled aluminum alloy automobile rear floor |
| title_sort | research on numerical simulation and integrated die casting process of large complex thin walled aluminum alloy automobile rear floor |
| topic | Integrated rear floor Numerical simulation Integrated die-casting Shrinkage and porosity Mechanical properties |
| url | http://www.sciencedirect.com/science/article/pii/S2590123025014690 |
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