An evaluation of direct pressure sensors for monitoring the aluminum die casting process Page: 50 of 130
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3. the convenient location of vents which allow the placement of vent flow
sensors,
4. the presence of walls which allow for assessing the effect of the process
variables on the quality of the casting in the blind (unvented) wall area versus
the ventable areas,
5. the diecasting size and shape which allow for easy radiographic determination
of porosity distribution and Archimedes' density measurements.
For the campaign at OSU ERC/NSM, four temperature probes (two on opposing
sides of the gate, and two on opposing sides of the pressure sensors) and two pressure
probes were used at the locations indicated in Figure 3.7. The thickness of the gate was
0.08 inch and the gate area was 0.32 inch2. The thickness of wall was 0.20 inch. The
operation variables decided for the chosen alloy, die and machine is provided in
APPENDIX C. 11.05 inch3 of Al alloy 390 melt was injected into the die cavity at a gate
velocity of 1400 inch/sec and at an injection pressure of 70.64 psi to achieve a cavity fill
time 12.1 ms. A looking force of 63,505 lbs was required to counter the intensification
pressure of 1413 psi. A PQ 2 analysis was performed and a flow rate 504 inch3/sec at the
required injection pressure was decided for a plunger diameter of 19.37 inches as shown
in APPENDIX D. The output of each sensor was collected using computer based data
acquisition system. The frequency of data collection was rather high because most of the
die casting events, such as cavity filling, pressure intensification, and vent exhausting,
occur in time frames of tens of milliseconds.36
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Zhang, X. An evaluation of direct pressure sensors for monitoring the aluminum die casting process, report, December 31, 1997; Columbus, Ohio. (https://digital.library.unt.edu/ark:/67531/metadc677846/m1/50/: accessed April 25, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.