Optimum Velocity Control of Die Casting Plunger Accounting for Air Entrapment and Shutting

Abstract

Die casting in mass production has the advantage of producing complex shapes precisely, but the disadvantage of air entrapment in high-speed injection molding. Plunger velocity control very effectively avoids air entrapment. Using computational fluid dynamics (CFD), we analyzed fluid behavior, the amount of air trapped, and air shutting caused by die casting plunger movement. We calculated optimum die casting plunger velocity control input to reduce or prevent air entrapment and air shutting in die casting products. We also conducted optimization using a genetic algorithm incorporating a CFD simulator.