Numerical Simulation And Process Optimization Of Low Pressure Die Casting For Faucet Body

The copper alloy is widely used in plumbing and bathing industry. Some products are madefrom copper alloy with low pressure die casting process such as high-grade faucet and valve.Low pressure die casting is a kind of metal liquid formation technology with nearly no workingallowance. It has great advantages on casting with high quality high efficacy and highcontrollability. Therefore low pressure die casting is the main process to produce faucet body.But low pressure die casting process is traditional and mainly based on production experience inmost of sanitary ware enterprises in china. It makes a long mold trial time high cost and lowefficiency which can’t gives the ability to quickly respond to market changing. This paper tries toimprove low pressure die casting for the quality of faucet boy by numerical simulation in orderto reduce the design trial production times and costs.Firstly the mold design is finished in this paper which manly contains gating system riserand exhaust system.The CAD model is bulit by using Pro/E software. Then compatabilityproblem between Pro/E and ProCAST is solved by finding a way about connect interfacebetween CAD/CAE software. Then the interface heat-transfer coefficient is found by the way oforthogonal experiment and inverse analysis.It gives accurate boundary conditions to buildingfinite element model. Then the low pressure die casting process of faucet body is simulated.Thedefects forecasted agree with the ones in practice which means a credible simulation.Meanwilethe intial mold is improved by analysis.Finaly the process optimization is put forward by meansof orthogonal test.The faucet body is produced with process optimization.The casting is fullyfilled with clear outline and the shrinkage porosity is in allowable range.It meets qualityrequirements.Taking the copper alloy faucet as study object this paper explores the applicacation ofnumerical simulation in low pressure die casting.It is aimed at improving traditional low pressuredies casting process based on CAE technology.It helps technolodist forecast foundry defects tooptimize casting process. It has great significance to enhance competitiveness for faucetenterprise.