The thesis analyzes the influence of thermal expansion of die casting tools on the occurrence of melt flashing in high-pressure die casting of aluminum. The research is based on a numerical approach combining casting simulations in MagmaSoft and thermo-mechanical analysis in Abaqus. The temperature field of die inserts was transferred to the numerical model of the tool, where deformations and contact conditions at the parting surfaces were evaluated. Based on the results, critical areas with insufficient sealing were identified and geometric corrections of the tool were proposed. The effectiveness of the proposed modifications was confirmed through additional simulations and validated in production. The results indicate that proper consideration of thermally induced deformations reduces flashing and improves tool performance.
|
