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HỘI THẢO QUỐC TẾ ATiGB LẦN THỨ CHÍN - The 9 ATiGB 2024 147

making mold cavities. [2] However, many other types Minitab software for evaluation by using the Taguchi
of steel, including FDAC steel, are expected to be method to provide the most suitable casting
capable of meeting the demands of HPDC. FDAC is a parameters for the experimental procedure. TABLE. I
type of steel with a hardness of 40-48 HRC that is show the most optimal casting parameters:
suited for mold cavities manufacturing. Foreign Table 1. Casting parameters
scientific research related to the topic is referenced,
thereby providing an overview of improvement Phase 1 velocity V1 (m/s) 0.15
efforts and developments in this field globally. These Phase 2 velocity V2 (m/s) 2.5
studies are not only a source of inspiration but also O
provide valuable information for this subject’s Melting temperature of ADC12 TADC12 ( C) 650
development. 2.3. Inspection method
Furthermore, a survey was conducted, and Altair After casting the required number of shots,
Inspire Cast [8], a fully functional software for continue to the next step in the research process: the
analyzing and simulating the HPDC process, was 3D scanning inspection method (photo scanning) [8].
chosen. Therefore, in this study, Altair Inspire Cast 3D scanners operate on the principle of projecting a
software was used for simulation. The simulation light area with a certain structure (usually stripes)
results of temperature, filling time, filling velocity, onto the sample surface.
and pressure are analyzed, and the options are This bright area will be simultaneously monitored
compared to find suitable parameters to apply to the
experimental process. by cameras for changes and recorded with all the data
that the light area shines on the sample. From the data
In this study, Minitab software [5] was used to obtained, the scanner will reconstruct the actual
perform statistical calculations to produce casting contour of the sample into a 3D model using the
parameters and draw conclusions about the changes scanning software.
in the mold cavities after the experimental process.
The Taguchi method is used to analyze and Advantages of 3D scanners: Using light areas for
determine the most reasonable and effective casting scanning gives structured light scanners the ability to
parameters for the experimental process. With capture a large area of data in just a few seconds
existing casting parameters, Altair Inspire Cast while still ensuring high accuracy and resolution.
software is used to provide simulation results on 2.4. Simulate the casting process
filling time, die material temperature during the From the available parameters, Altair Inspire Cast
process, die material flows, filling velocity, insert software is used to produce simulation results on
erosion, pressure, shrinkage, part displacement, and
mold temperature [1]. At the same time, the filling time, die material temperature, die material
flow, die material flow velocity, insert erosion,
simulation results also help point out defects in the
mold cavities such as air holes and weld lines. After molding pressure, shrinkage, part displacement, and
the experimental process was complete with the mold cavity temperature. At the same time, the
specified number of shots, the 3D scanning method simulation results also help point out defects in the
was used to check and measure the dimensions and mold cavity, such as air holes and weld lines.
parameters of the mold cavities’ surface. With those 3. ANALYZE AND EVALUATE THE
results, the ANOVA One-way statistical analysis RESULTS
method will help analyze the variation of the inserts’ After the process of casting experiments and
dimensions.
measurements using the 3D scanning method, the
2. DIE MATERIAL, INSERT MATERIALS, results received on insert deformation after a specific
EXPERIMENT METHOD, AND SIMULATIONS number of shots help make assessments on the
OF THE CASTING PROCESS effectiveness and limitations of each type of material.
2.1. Die material and insert material After analyzing the images from the 3D scanning
process, the conclusions were shown in images and
The part used for this research is DPCT–Top, a graphs.
camera anti-vibration cushion mounted on a drone
manufactured by Real-Time Robotics. The part is 3.1. Core inserts
designed with thin walls and is very difficult to Important locations on core inserts that have the
manufacture. The material used for casting is ACD12 most significant deformation after shots were chosen
aluminum. to evaluate. Fig. 1 shows the variation values of
The mold is designed to produce one product per deformation on FDAC and SKD61 core inserts.
casting. SKD61 steel and FDAC steel are two
materials used to examine the durability of the insert.
2.2. Casting parameters
The Taguchi method is used for optimizing
casting parameters. All available data was loaded into
ISBN: 978-604-80-9779-0