Title: Process optimization of an innovative combination of high pressure die casting and sheet metal forming using casting simulation with Simcenter STAR-CCM+
High Pressure Die Casting (HPDC) is a fast and inexpensive process for mass manufacturing of precision components, resulting in excellent dimensional accuracy and requiring minimal machining. A new development in HPDC is a hybrid process, which casts aluminum around a steel or aluminum metal sheet. In this way the hybrid process combines the strength of the metal sheet with the geometrical flexibility of the casting process.
Metal sheets with a special design structural surface are introduced into a HPDC die. Hot melt is pressed into the die and, at the same time, into the surface structure of the metal sheet. During solidification the melt forms a strong bond to the metal sheet and in this way a strong connection between metal sheet and cast part. Gluing or welding of sheet and cast part is no longer necessary and one production step can be omitted.
The talk demonstrates how fully coupled casting simulation with Simcenter STAR-CCM+ can be used to simulate the hybrid HPDC process with a focus on the wetting of the metal sheet surface by the hot melt and the forming of the bond between sheet and cast part. Melt flow, filling of the structural surface and wetting behavior can be analyzed in detail. The influence of process parameter like piston pressure and geometrical aspects, especially the surface structure of the metal sheet, are investigated and optimized process and surface parameter identified.