Open Access Dissertation
The purpose of this study was to investigate the relationships between casting features (including weight, average thickness, surface area, and outside diameter) and casting process variables (including cavity fill time, gate velocity, and gate area) for aluminum die castings. Historical data of good quality aluminum round castings of the Kiowa Corporation in Marshalltown, Iowa, were used in the correlation analysis. The correlation analysis consisted of determining the following: (1) the correlation of one casting process variable and one casting feature. (2) the multiple correlation of one casting process variable and a combination of several casting features. The results of statistical analyses indicated that there are significant correlations between some casting features and casting process variables. Average thickness had the highest correlation with cavity fill time and gate velocity. Outside diameter had the highest correlation with gate area. Since all six correlations between pairs of casting features were significant, the use of a second casting feature in the multiple regression equation for predicting casting process variables from casting features does not result in a significant difference. Therefore, for round aluminum die castings of alloy A380 with the metal temperature 1220(DEGREES)F, in sizes of 2.7 to 16 inches, made by a horizontal cold chamber machine with a die temperature of 350(DEGREES)F, this study suggests that the design of gate area should be based on casting outside diameter, and that cavity fill time and gate velocity should be based on casting average thickness. Casting cavity fill time can be predicted from casting average thickness by using the following linear regression equation: Cavity Fill Time (sec) = 0.0059 + 0.3757 x Average Thickness (in). Gate velocity can be predicted from average thickness by using the following linear regression equation: Gate Velocity (ft/sec) = 133.5828 - 152.2890 x Average Thickness (in). Gate area can be predicted from outside diameter by using the following linear regression equation: Gate Area (in('2)) = 0.0092 + 0.0345 x Outside Diameter (in).
Year of Submission
Doctor of Industrial Technology
Department of Industrial Technology
James P. LaRue (Advisor)
1 PDF file (viii, 96 pages)
©1986 Hsin-Yen Chen
Chen, Hsin-Yen, "Relationships between casting features and cavity fill time, gate velocity, and gate area for aluminum die castings" (1986). Theses and Dissertations @ UNI. 879.