Improvement and validation of Zamak die casting moulds

The automotive industry, like many other industries, uses a wide range of parts produced by the die-cast process. Parts like engine blocks, wheel spacers, alternator housings and command cable terminals, are made by die casting with different kinds of materials like aluminium and zinc alloys. Despite being a reliable process both in terms of quantity and quality, it is very important to keep the process parameters controlled, in order to achieve a minimum percentage of defective parts, which may be caused by several factors such as, porosities, segregations, incomplete fill, soldering, cracks, etc. The main goal of the die casting industry is to achieve the zero per cent defects target, a goal that goes along with the automotive industry and its quality system, and to accomplish this objective the stakeholders need to invest in research and development. In the casting industry, for instance, it is very important to have a complete knowledge of the entire process developed inside the casting machine, from the melting pot to the die, in order to obtain data so one can improve the filling parameters, machine parts, and moulds. The focus of the presented study is the improvement of the methodologies used to design moulds for control cable terminals in Zamak alloys. The work starts by characterizing the flow happening inside the mould at the moment of cavity fill by analysing computer fluid dynamics simulations (CFD). The study proceeds by quantifying the porosities detected on cut terminal surfaces, and the ultimate goal is achieved with the modification of molten metal flow systems, like channels and sprues, and the introduction of venting systems, with a resource to mathematical and geometrical calculus developed in MATLAB® specifically for that purpose. The paper ends with the validation of the improvements, by comparing the initial results with the ones obtained through an improved mould, building bases for novel design concepts of moulds for this kind of parts, as well as new studies trying to improve the results now achieved.