Finite Element Analysis And Topology Optimization For The Clamping Mechanism Templates Of Large-scale Die Casting Machine

Die casting is an efficient way for metal forming process that there is little or no metalcutting, it’s characteristic is that high voltage was applied to the molten metal to make theliquid metal can be smoothly filled cavity, than obtain the necessary parts after cooling.Casting technology is a special molding method and was widely used to produces a widevariety of metal parts in modern industry. Die casting machine is the core equipment ofcasting technology, with the development of computer technology from last century, finiteelement techniques was generally applied to the development process of die-castingmachines by Europe, Japan and other developed countries. This technique can largelyimprove product quality, shorten development time and enhance market competitiveness.Compared to developed countries, the development of die casting machine is mainly based onexperience in our country, so the development cycle is long and there are some gaps in aspectsof stability, reliability, etc. Therefore, in order to improve market competitiveness, we mustadopt advanced design methods to shorten the development time of die casting machine andsaving development costs. In the overall structure of the die casting machine, the head plateand the middle plate are the main force components of the clamping mechanism, and it’sstrength and stiffness directly affect the reliability and stability of the clamping mechanism. Inorder to identify problems early in the design phase and to reduce the number of prototypestests, In this paper have a series study of the middle plate and head plate of DM3500diecasting machines of Guangdong Yizumi Die Casting Technology Ltd. using the finite elementtechnique. The main contents of this paper include:(1) Establish the virtual prototype model of the die casting machine, in order to improvethe simulation accuracy replace the rigid hinge with flexible hinge to dynamics analysis of thewhole die casting machine with the multi-body dynamics software ADAMS, acquire theclamping force in the hinge holes of middle plate, testing the clamping characteristics of thecasting machine.(2) According to the dynamic simulation results, analysis the static contacts of theclamping mechanism. Establish finite element model with the professional softwareHYPERMESH to mesh the middle plate and head plate, than export the model to ANSYSsoftware for simulation.(3) Confirm the boundary conditions according the theory for thermal analysis of themiddle plate and the head plate. The obtained temperature field was loaded into the structure field as a body load for thermal stress analysis, load both clamping force and thermal loads tothe clamping mechanism according the results of kinetic analysis and thermal analysis forthermal-structure coupling analysis.(4) Topology optimization the structure of middle plate use the method of variabledensity topology optimization, redesigned the board structure based on the density cloud.Analysis the mechanical load and mechanic-thermal coupling effect on the model aftertopology optimization, validate the deformation and stress situation of the middle plate, anddetect the influence of the topology structure to the deformation and stress of head plate.