Author Contributions
Conceptualization, J.M. and Š.G.; methodology, T.C. and Š.G.; software, D.G. and T.C.; validation, J.M., Š.G. and J.H.; formal analysis, L.K.; investigation, J.M. and Š.G.; resources, T.C.; data curation, J.P., Š.G. and D.G.; writing—original draft preparation, J.M.; writing—review and editing, Š.G. and J.H.; visualization, J.M. and T.C.; supervision, J.P. and L.K.; project administration, J.H.; funding acquisition, Š.G. All authors have read and agreed to the published version of the manuscript.
Figure 1.
Scheme of attachment of the ingate to the cylindrical area ingate area AI.
Figure 1.
Scheme of attachment of the ingate to the cylindrical area ingate area AI.
Figure 2.
Cross section of the gating channel.
Figure 2.
Cross section of the gating channel.
Figure 3.
3D model of electric motor flange.
Figure 3.
3D model of electric motor flange.
Figure 4.
3D model of designed gating system.
Figure 4.
3D model of designed gating system.
Figure 5.
The melt jet is outside the core.
Figure 5.
The melt jet is outside the core.
Figure 6.
The melt jet is directed right towards the core.
Figure 6.
The melt jet is directed right towards the core.
Figure 7.
Formation of the melt jet outside the cores.
Figure 7.
Formation of the melt jet outside the cores.
Figure 8.
Formation of the melt jet when hitting against the core.
Figure 8.
Formation of the melt jet when hitting against the core.
Figure 9.
Distribution of defects for incorrect of cast forming—contractions 2.8%.
Figure 9.
Distribution of defects for incorrect of cast forming—contractions 2.8%.
Figure 10.
Distribution of defects in gating system—contractions 5.4%.
Figure 10.
Distribution of defects in gating system—contractions 5.4%.
Figure 11.
Temperature in the ingate.
Figure 11.
Temperature in the ingate.
Figure 12.
Distribution of defects in adjusted gating system—contractions 0%.
Figure 12.
Distribution of defects in adjusted gating system—contractions 0%.
Figure 13.
Relationship between permanent deformation and change of the ingate height.
Figure 13.
Relationship between permanent deformation and change of the ingate height.
Figure 14.
Relationship between the hardness of the diecast part HB and change in the ingate height.
Figure 14.
Relationship between the hardness of the diecast part HB and change in the ingate height.
Figure 15.
RTG—Sample 4.C.
Figure 15.
RTG—Sample 4.C.
Figure 16.
RTG—Sample 1.B.
Figure 16.
RTG—Sample 1.B.
Figure 17.
RTG—Sample 2.C.
Figure 17.
RTG—Sample 2.C.
Figure 18.
Microstructure of the edge part of the casting.
Figure 18.
Microstructure of the edge part of the casting.
Table 1.
Permitted values of material solidification depending on the wall thickness.
Table 1.
Permitted values of material solidification depending on the wall thickness.
Wall Thickness [mm] | Permitted Values of Material S (%) |
---|
Aluminium | Magnesium | Zinc |
---|
<0.8 | 5 | 10 | 5–15 |
0.8–1.25 | 5–25 | 5–15 | 10–20 |
1.25–2 | 15–35 | 10–25 | 15–30 |
3–2 | 20–50 | 20–35 | 20–35 |
Table 2.
Recommended values of the flowing speed of the melt in the ingate.
Table 2.
Recommended values of the flowing speed of the melt in the ingate.
Type of Alloy | Recommended Values of the Flowing Speed of the Melt in the Ingate (m·s−1) |
---|
Standard Casting | Vacuum Casting |
---|
Aluminium | 20–60 | 15–30 |
Zinc | 30–50 | |
Magnesium | 40–60 | |
Copper | 20–50 | |
Table 3.
Recommended volumes of flow.
Table 3.
Recommended volumes of flow.
Characteristic Wall Thickness of a Gate Segment (mm) | Flow Volume, Percentage Ratio Out of Segment Volume |
---|
For High Surface Quality | For Lower Surface Quality |
---|
0.90 | 150% | 75% |
1.30 | 100% | 50% |
1.80 | 50% | 25% |
2.50 | 25% | 25% |
3.20 | - | - |
Table 4.
Weight and volume characteristic of die-cast part.
Table 4.
Weight and volume characteristic of die-cast part.
Quantity | Value |
---|
Alloy | EN AC 47100—AlSi12Cu(Fe) |
Die-cast part volume | 51,697.9 × 10−9 m3 |
Alloy density | 2650 kg·m−3 |
Die-cast part weight | 0.136 kg |
Table 5.
Dimension of the gating system.
Table 5.
Dimension of the gating system.
The Main Gating Channel | The Side Gating Channel |
---|
Parameter | Value | Parameter | Value |
---|
Area/A | 811.36 × 10−6 m2 | Area/A | 368.8 × 10−6 m2 |
Height/CT | 14.59 × 10−3 m | Height/CT | 14.59 × 10−3 m |
Weight/CB | 51.70 × 10−3 m | Weight/CB | 29.18 × 10−3 m |
Length/L | 264 × 10−3 m | Length/L | 280 × 10−3 m |
Ingate |
The area/AI | 75.97 × 10−6 m2 |
Length/a | 60.968 × 10−3 m |
Height/b | 1.25 × 10−3 m |
Table 6.
Adjusted dimensions of gating channels.
Table 6.
Adjusted dimensions of gating channels.
The Main Gating Channel | The Side Gating Channels |
---|
Parameter | Value | Parameter | Value |
---|
Area/A | 497.5 × 10−6 m2 | Area/A | 242.19 × 10−6 m2 |
Height/CT | 14.59 × 10−3 m | Height/CT | 14.59 × 10−3 m |
Weight/CB | 38.0 × 10−3 m | Weight/CB | 20.5 × 10−3 m |
Length/L | 264 × 10−3 m | Length/L | 280 × 10−3 m |
Table 7.
Chemical composition of experimental meltage of used alloy % content of elements.
Table 7.
Chemical composition of experimental meltage of used alloy % content of elements.
Chemical Composition of the Experimental Cast of the Applied Alloy % of Elements Content |
---|
Al | Si | Fe | Cu | Mn | Mg | Cr | Ni | Zn | Pb | Sn | Ti |
85.50 | 11.82 | 0.76 | 1.03 | 0.27 | 0.18 | 0.03 | 0.12 | 0.30 | 0.03 | 0.03 | 0.03 |
Table 8.
Values of permanent deformation “s” in relation to change of the ingate height.
Table 8.
Values of permanent deformation “s” in relation to change of the ingate height.
Sample No. | Gate Height (mm) | Gate Weight (mm) | | Permanent Deformation “s” (mm) |
---|
Arithmetic Average |
---|
1.A | 1.25 | 60.968 | 0.064 | 0.066 |
1.B | 0.068 |
1.C | 0.065 |
2.A | 1.03 | 0.048 | 0.053 |
2.B | 0.057 |
2.C | 0.055 |
3.A | 0.92 | 0.042 | 0.044 |
3.B | 0.044 |
3.C | 0.047 |
4.A | 0.82 | 0.035 | 0.033 |
4.B | 0.033 |
4.C | 0.032 |
5.A | 0.75 | 0.057 | 0.058 |
5.B | 0.054 |
5.C | 0.062 |
Table 9.
Values of the surface hardness of the die-cast part “HB” in relation to change of the ingate height.
Table 9.
Values of the surface hardness of the die-cast part “HB” in relation to change of the ingate height.
Sample No. | Gate Height (mm) | Gate Weight (mm) | Measurement | Arithmetic Average |
---|
No. 1 | No. 2 | No. 3 | No. 4 | No. 5 |
---|
1 | 1.25 | 60.968 | 108 HB | 107 HB | 108 HB | 107 HB | 107 HB | 107 HB |
2 | 1.03 | 109 HB | 107 HB | 106 HB | 107 HB | 106 HB | 107 HB |
3 | 0.92 | 106 HB | 108 HB | 107 HB | 108 HB | 107 HB | 107 HB |
4 | 0.82 | 106 HB | 104 HB | 107 HB | 107 HB | 107 HB | 106 HB |
5 | 0.75 | 105 HB | 107 HB | 105 HB | 106 HB | 107 HB | 106 HB |