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J M a t e r S c i T e c h n 0 1 ,V 0 1 2 4N o 1 ,2 0 0 8T h i n - - W a l lA l u m i n u mD i e - C a s t i n gT e c h n o l o g yf o rD e v e l o p m e n to fN o t e b o o kC o m p u t e rH o u s i n gC h a n g - S e o g K a n g t ,J a e 一kC h o ,C h a n g - Y e o lJ e o n g , S e W e o nC h o ia n dY o u n g - C h a nI G mK o r e aI n s t i t u t eo fI n d u s t r i a lT e c h n o l o g y ,G w a n g j u ,K o r e a M a n u s c r i p tr e c e i v e dS e p t e m b e r3 ,2 0 0 7 6 5S i l i c o n b a s e da l u m i n u mc a s t i n ga l l o y sa r ek n o w nt ob eo n eo ft h em o s tw i d e l yu s e da l l o ys y s t e m sm a i n l yd u et ot h e irs u p e r i o rc a s t l n gc h a r a c t e r i s t i c sa n du n i q u ec o m b i n a t i o no fm e c h a n i c a Ia n dp h y s i c a Ip r o p e r t i e s H o w e v e r m a n u f a c t u r i n go ft h i n w a l l e da l u m i n u md i e c a s t i n gc o m p o n e n t s ,I e s st h a nI 0m mi nt h i c k n e s s i sg e n e r a l l yk n o w nt ob ev e r yd i f f i c u l tt a s kt oa c h i e v ea I u m i n u mc a s t i n ga l l o y sw i t hh i g hf l u i d i t y T h e r e f o r e i nt h i ss t u d y t h eo p t i m a ld i e c a s t i n gc o n d i t i o n sf o rp r o d u c i n g2 9 7m mx2 1 0m mx0 7m mt h i n w a l l e da l u m i n u mc o m p o n e n tw a se x a m i n e de x p e r i m e n t a l l yb yu s i n g2d i f f e r e n tg a t i n gs y s t e m s ,t a n g e n t i a la n ds p l i tt y p e a n dv e n td e s i g n F ur t h e r m o r e ,c o m p u t a t i o n a ls o l i d i f i c a t i o ns i m u l a t i o nw a sa l s oc o n d u c t e d T h er e s u l t ss h o w e dt h a ts p l i tt y p eg a t i n gs y s t e mw a sp r e f e r a b l eg a t i n gd e s i g nt h a nt a n g e n t i a lt y p eg a ta n gs y s t e ma tt h ep o m to fv i e wo fs o u n d n e s so fc a s t i n ga n dd i s t o r t i o ng e n e r a t e da f t e rs o l i d i f i c a t i o n I tw a sa l s of o u n dt h a tp r o p e rv e n td e s i g nw a so n eo ft h em o s ti m p o r t a n tf a c t o r sf o rp r o d u c i n gt h i n w a I | c a s t i n gc o m p o n e n t sb e c a u s ei tw a si m p o r t a n tf o rt h ef u l l m e n to ft h et h i n w a l lc a v i t ya n dt h em i n i m i z a t i o no ft h ec a s t i n gd i s t o r t i o n K E YW O R D S :A l u m i n u m ;T h i n - - w a l ld i e c a s t i n g ;N o t e b o o kc o m p u t e rh o u s i n g ;C o l dc h a m b e rd i e c a s t i n gm a c h i n e1 I n t r o d u c t i o nA m o n gt h ea l u m i n u mc a s t i n ga l l o y s t h eA 1 一S ib a s e da l l o ys y s t e m sa r eo n eo ft h em o s tw i d e l yu s e da l l o ys y s t e m sb e c a u s eo ft h e i ru n i q u ec h a r a c t e r i s t i c ss u c ha s1 0 wd e n s i t y ,m o d e r a t e l y h i g hs t r e n g t h ,a n dg o o dc a s t a b i l i t y , e t c 13 j R e c e n t l y , t h ed e m a n df o rl i g h t w e i g h ta l l o y si 1 1e l e c t r i c e l e c t r o n i ca n da u t o H I o b i l ec o m p o n e n th o u s i n g s u s i n ga l u m i n u mh a sb e e ng r e a t l yi n c r e a s e dm a i n l yb e c a u s ei ti sl i g h t w e i g h th a v i n gh i g hd a m p i n gc a p a c i t ya n dd e n tr e s i s t a n c ec o n l p a r e dt op l a s t i c s H o w e v e r i ti sg e n e r a l l yk n o w nt h a tm a n u f a c t u r i n go ft h i n w a l la l u m i n u mc o m p o n e n tw i t hat h i c k n e s sl e s st h a n1 0m mb yu s i n gh i g hp r e s s u r ed i ec a s t i n gp r o c e s si sq u i t ed i f f i c u l td u et oi t sl o wf l u i d i t y T h i sl e a d st ot h el i i n i t , e da p p l i c a t i o no ft h ea l u m i n u ma l l o yi nt h ef i e l d so fh o u s i n go fe l e c t r i c e l e c t r o n i cc o m p o n e n t ss u c ha sn o t e b o o kc o m p u t e ra n dc e l l u l a rp h o n e ,e t c T h e r e f o r e ,i nt h i ss t u d y ,d i e c a s t i n gp r o c e s st e c h n o l o g yf o rt h ep r o d u c t i o no ft h i n w a l la l u m i n u mc o m p o n e n t sb a s e do nt h ei n v e s t i g a t i o no ft h eo p t i m a ld i ed e s i g ni n c l u d i n gr u n n e r sa n dg a t i n gs y s t e ma n dc a s t i n gc o n d i t i o n sw a si n v e s t i g a t e d M o r e o v e r ,e x p e r i m e n t a le x a m i n a t i o n so fg a t i n gd e s i g ne l -f e c t so nt h ef a b r i c a t i o np r o c e s s i n go fs o u n dt h i n w a l la l u m i n u mn o t e b o o kh o u s i n gw i t hat h i c k n e s so fl e s st h a n0 8n l n l 2 E x p e r i m e n t a lP r i o rt ot h ea c t u a ld i e c a s t i n ge x p e r i m e n t c a s t i n gs i m u l a t i o nv c a sc o n d u c t e dt os e tu pt h ed i e c a s t i n ga n dm e l tc o n d i t i o n s D i e c a s t i n gd i em a d eo u to fH 1 3t o o ls t e e lf o rt h et h i n w a l ln o t e b o o kh o u s i n gi ns i z eo f2 1 0H i m x 2 9 7n l n l 0 7i n n lw a sd e s i g n e da n df a b r i c a t e df o rt h ee x p e r i m e n t A ss h o w ni nF i g 1 、十P h D ,t ow h o mc or 1 1 e 8 p o n d e n c es h o u l db ea d d r e s s e dE m a i hc s k a n 9 7 k i t e c h r e k r t h e2d i f f e r e n tt y p e so fg a t i n gs y s t e m ,t a n g e n t i a lt y p ea n ds p l i tt y p e ,w e r eu s e df o rt h i si n v e s t i g a t i o n Ac o m m e r c i a lA L D C l 2a l u m i n u md i e c a s t i n ga l l o y ( A 1 一( 9 6 1 2 ) s i 一( 1 53 5 ) C u ,T a b l e1 ) w a sm e l t e du pt o7 8 0 。Ca n dt h ed i ew a sh e a t e du pt o2 3 0 。Cb e f o r et h ed i ec a s t i n g T h em a j o rs p e c i f i c a t i o n so ft h ec o l dc h a m b e rd i e c a s t i n gm a c h i n ef F i g 2 ) ,u s e df o rt h i ss t u d ya r es h o w ni nT a b l e2 M o l t e na l u m i n u ma l l o yw a si n j e c t e di n t ot h ed i ec a v i t yu n d e rt h ec o n d i t i o n so f0 3 5m si ni n j e c t i o ns p e e du n t i lt h ep l u n g e rt r a v e l e du pt o3 7 0H i mi ns h o ts l e e v ea n dt h e nt h ei n1iections p e e dw a sa c c e l e r a t e di n e a r l yt ot h eh i g hi n j e c t i o ns p e e do f2 0 ,2 5 ,3 0 3 5 4 0a n d4 5m sf r o n l3 7 0i n mt o3 9 0H i mi ns h o ts l e e v e T a b l e3s h o w st h es u m m a r yo fd i e c a s t i n gc o n d i t i o n sf o rt h i si n v e s t i g a t i o n 3 R e s u l t sa n dD i s c u s s i o nT h es o l i d i 蠡c a t i o ns i m u l a t i o nw a sc o n d u c t e df o r2d i f f e r e n tg a t ed e s i g n s ,t a n g e n t i a la n ds p l i tt y p ep r i o rt ot h ed i e c a s t i n ge x p e r i m e n t T h ef l o wp a t t e r na n dt e m p e r a t u r ed i s t r i b u t i o nd u r i n gf i l l i n go fa l u m i n u mm e l tw i t ht h eg a t ed e s i g n ss t u d i e da r es h o w ni nF i g 3 I tw a sf o u n dt h a tb o t hg a t ed e s i g n se x h i b i t e dq u i t eu n i f o r mm e l tf l o wt h r o u g h o u tt h ef i l l i n go ft h ec a v i t y H o w e v e r ,t h et a n g e n t i a lt y p eg a t ed e s i g nr e s u i t e di nt h em e l tt e m p e r a t u r ed r o p p e da r e afc i r c l e di i lF i g 3 ( a ) ) a tt h el a s ts t a g eo ff i l l i n gw h i l et i l es p l i tt y p eg a t ed e s i g na l l o w e dt h em e l tt of i l lt h ec a v i t ya b o v et h el i q u i d u st e m p e r a t u r e A sm e n t i o n e d ,a c t u a ld i e c a s t i n ge x p e r i m e n t sw e r ec o n d u c t e df o rt h en o t e b o o kc o m p u t e rh o u s i n gi ns i z eo f2 1 0m i D _ 2 9 7n l n l X 0 7t o n i F i g u r e4s h o w st h er e s u l t a n tc a s t i n g sw i t hv a r i e dh i g hs p e e di n j e c t i o nf r o m2 0t o4 5m sw h i l e1 0 ws p e e di n j e c t i o nw a sf i x e dt o0 3 5m s A ss h o w n b o t hg a t ed e s i g n sa l l o w e df i l l i n gt h ec a s t i n gw i t hh i g hs p e e di n j e c t i o no fm o r et h a n3 0m s H o w e v e r ,l e s st h a n3 0m so fh i g hs p e e di n j e c t i o nf a i l e dt of i l lt h et h i n w a l lc a v i t y I tw a s 万方数据6 6J M a t e r S c i T e c h n 0 1 ,V 0 1 2 4N o 1 ,2 0 0 8T a b l e1C h e m i c a lc o m p o s i t i o n so fA L D C l 2a l l o y ( i nw tp c t )T a b l e2S p e c i f i c a t i o no fd i e c a s t i n gm a c h i n e5 2 5 04 9 0砂7 0T a b l e3D i e c a s t i n ge x p e r i m e n tc o n d i t i o n s7 8 02 3 02 0 ,2 5 ,3 0 ,3 5 ,4 0 ,4 50 3 5F i g 1S c h e m a t i ci l l u s t r a t i o nn o t e b o o kh o u s i n g ( 2 1 0m m x 2 9 7I l l I l l X o 8n l m ) a n d2d i f f e r e n tg a t ed e s i g n s :( a ) t a ng e n t i a lt y p e ,( b ) s p l i tt y p eF i g 2H i g hs p e e dd i e c a s t i n gm a c h i n e 万方数据EE、CQ芑凸J M a t e r S c i T e c h n 0 1 ,V 0 1 2 4N o 1 ,2 0 0 8F i g 3S i m u l a t i o nr e s u l t so f2d i f f e r e n tg a t ed e s i g n s :( a ) t a n g e n t i a lt y p e ,( b ) s p l i tt y p eF i g 4D i e c a s t i n gr e s u l t sb yv a r y i n gt h eh i g hs p e e di n j e c t i o n :( a ) t a n g e n t i a lt y p e ,( b ) s p l i tt y p eD i s t a n c e ,m mF i g 5D i s t o r t i o no ft a n g e n t i a la n ds p l i tt y p eg a t i n gs y s t e ma f t e rt h er e m o v a lo fg a t e sa l s of o u n dt h a tt h et a n g e n t i a lt y p eg a t ed e s i g nw a sn o ta b l et o6 1 lt h eo v e r f l o we v e na tt h eh i g h e s ti n j e c t i o ns p e e du s e df o rt h i si n v e s t i g a t i o n M o r e o v e r ,t h et a n g e n t i a lt y p eg a t i n gs y s t e mr e s u l t e di nm o r ed i s t o r t i o no ft h ec a s t i n ga f t e rt h er e m o v a lo ft h eg a t e 6 7I nF i g 5 ,t h ea m o u n to fd i s t o r t i o nm e a s u r e da f t e rr e m o v a lo fe a c hg a t i n gs y s t e mw a sd i s p l a y e d T h er e s u l tc l e a r l ys h o w e dt h a tt h et a n g e n t i a lt y p eg a t i n gs y s t e mc o u l dr e s u l t e di nm o r es e v e r ed i s t o r t i o nt h a ns p l i tt y p e S i n c en o t e b o o kh o u s i n gf a b r i c a t e di nt h i sr e s e a r c hw a so n l y0 7m mi nt h i c k n e s s ,t h es t r e s sb u i l du pb e c a u s eo ft h es h r i n k a g eo fc a s t i n ga f t e rt h ec o m p l e t i o no fs o l i d i f i c a t i o nw a sa ni m p o r t a n tf a c t o rt oc o n s i d e rf o rt h em a s sp r o d u c t i o no ft h en o t e b o o kh o u s i n g T h e r e f o r e ,i tw a sc o n c l u d e dt h a tt h es p l i tt y p eg a t ed e s i g nw a sb e t t e rt h a nt h et a n g e n t i a lt y p eb e c a u s eo ft h ea f o r e m e n t i o n e dm a t t e r s H o w e v e r e v e nw i t hs p l i tt y p eg a t ed e s i g nt h e r ew e r ec a s t i n gd e f e c t ss u c ha sf l o wl i n ea n dm i s r u nd u r i n gd i e c a s t i n g T h e r e f o r e ,t w om a j o rm o d i f i c a t i o n sw e r ei n t r o d u c e d O n ew a st h ei n c r e a s eo ft h eo v e r f l o wa n dv e n ts i z e s T h ev o l u m eo ft h eo v e r f l o ww a si n c r e a s e da b o u t7 0 f f r o m4 4 0 0m m 3t o7 5 0 0m m 3 )a n dt h eo v e r f l o wi n g a t e l e n g t hw a sa l s oi n c r e a s e df r O l n1 3 5m mt o3 0m mi nt o t a ll e n g t hf o rt h eb e t t e rf l o wo fa i ri nt h ed i ec a v i t y M o r e o v e r ,u p p e rp a r to fs l e e v ew a sm a c h i n e dt oh a v ei n c l i n e ds l o p ea ss h o w ni nF i g 6 万方数据6 8J M a t e r S c i T e c h n 0 1 ,V 0 1 2 4N o 1 ,2 0 0 8F i g 6S c h e m a t i ci l l u s t r a t i o no ft h ei n c l i n e ds l o p es l e e v eF i g 7T h i n w a l ln o t e b o o kh o u s i n gw i t hat h i c k n e s so fO 7m i l lG a t es y s t e mL o c a t i o nF i g 8T h et h i c k n e s so ft h i n w a l ln o t e b o o kh o u s i n gt om i n i m i z et h et u r b u l e n c ea n da i re n t r a p m e n ti n s i d eo ft h es l e e v ed u r i n gi niectionB e c a u s et h es l e e v eW a Sf i l l e dw i t ha l u m i n u ml e s st h a n3 0 f m i n i m u mo f4 0 o f s l e e v ef i l l i n gi sr e c o m m e n d e di nd i e ,c a s t i n gp r o c e s si n f i e l d lr e s u l t i n gl a r g ea m o u n to fe n t r a p p e da i ra n dh i g ht u r b u l e n c ed u r i n gi n j e c t i o nL 4 J A st h eF i g 6s h o w s ,t h em a c h i n e ds l o p ew o u l dh e l pa i ri n s i d eo ft h es l e e v et of l o wo u tm o r ee a s i l yd u r i n gi nt h a 土i e c t i o nS Ot h ea i re n t r a p m e n ti nt h em e l tw o u l db em i n i m i z e d W i t h - t w om o d i f i c a t i o n sm e n t i o n e de a r l i e r ,s o u n dt h i n w a l ln o t e b o o kh o u s i n gc a s t i n gw i t hl e s sd e f e c tW a Ss u c c e s s f i f l l yf a b r i c a t e d ( F i g 7 1 T h e r ef o u n dt ob el e s sf l o wl i n e ,c r a c ka n dm i s r u nd e f e c t si nt h ec a s t i n g T h et h i c k n e s so ft h ec a s t i n gw a sm e a s u r e df F i g 8 1 I nl e f tf i g u r e ,t h el o c a t i o n so ft h et h i c k n e s sm e a s u r e da n da r es h o w na n dt h er i g h tf i g u r es h o w st h en l e a s u r e dt h i c k EE、o亡芏。Iu I 万方数据J M a t e r S c i T e c h n 0 1 ,V 0 1 2 4N o 1 ,2 0 0 8n e s so ft h ec a s t i n g T h et h i c k n e s sw a sf o u n dt ob eq u i t eu n i f o r ma n da v e r a g et h i c k n e s so f0 6 7n l n lw a so b t a i n e d B e c a u s et h ec a s t i n gw a ss ot h i n ,l e s st h a n0 7i n n l ,t h ee一i e c t i o nf r o n lt h ed i ea f t e r lt h es o l i d i f i c a t i o nbecanlev e r yi m p o r t a n tT b i nw a lc a s t i n gc o u l db eb e n to re v e nc r a c k e dd u r i n gt h ee j e c t i o n ;t h e r e f o r e ,t h en u m b e ro fe j e c t o rp i na n di t s1 a yo u tw e r ev e r yc r i t i c a li nd i ed e s i g n M o r e o v e r ,t h eu s eo fd i et e m p e r a t u r ec o n t r o l l e rW a Sa l s oa ni m p o r t a n tf a c t o rf o rf u l f i l l m e n to fd i ec a v i t yf o rt h i n w a l ld i e c a s t i n g I tw a sf o I u n dt h a tw i t h o u tt h ed i et e m p e r a t u r ec o n t r o l l e r t h ed i eW a Sn o th e a t e du pS O f f i c i e n t l ye v e nw i t hm o r et h a n2 0t i m e so fi n j e c t i o n W h e nt h ed i ed i dn o tb eh e a t e du pt oa p p r o p r i a t et e m p e r a t u r e ,t h em e l tw o u l db er a p i d l yc o o l e dd o w nw h e ni ti n j e c t e di n s i d eo ft h ec o l dd i ec a v i t y A sar e s u l t s e v e r ec a s t i n gd e f e c t si n e l u d i n gm i s r u na n dc r a c k sw e r ee x h i b i t e dw i t h o u td i et e m p e r a t u r ec o n t r 0 1 4 C o n c l u s i o n( 1 ) B e t w e e nt a n g e n t i a la n ds p l i t , t y p eg a t ed e s i g n s ,s p l i tt y p eg a t i n gs y s t e mW a Sf o u n dt ob eb e t t e rf o rt h i n w a l ld i e c a s t i n gb e c a u s et h em e l tf l o w sm o r eu n i f o r m l yi n s i d et h ed i ec a v i t y ( 2 ) A st h em e l tr e a c h e dt h ei n g a t e ,t h eh i g hs p e e di n j e c t i o nn e e d e dt ob eh i g h e rt h a n3 0m S p r e f e r a b l y4 5m s f o rs o u n dt h i n w a l ld i e c a s t i n gi ns i z eo f6 9n o t e b o o kc o m p u t e rh o u s i n g ( 3 ) T h et h i c k n e s sw a su n i f o r mt h r o u g h o u tt h ec a s t i n ga n da v e r a g et h i c k n e s so f0 6 7n U l lw a so b t a i n e d ( 4 ) F o rt h i n w a l la l u m i n u md i e c a s t i n g ,t h el o c a t i o na n dt h es i z eo fa i rv e n ta n do v e r f l o ww e r ei m p o r t a n tf a c t o r sf o rm i n i m i z i n gt h ef l o wl i n ea n di n i s r u nd e f e c t si nt h ec a s t i n g ( 5 ) I n c l i n e ds l o p es l e e v ed e s i g nW a Sh e l p f u lf o ra i re n t r a p p e di n s i d eo f s l e e v et of l o wo u td u r i n gi n j e c t i o n ( 6 ) B e c a u s et h ec a s t i n gv o l u m eW a Sq u i t es m a l l ,i ti si m p o r t a n tt oC O n t r o lt h ed i et e m p e r a t u r e3 8h i g h3 8p o s s i b l e A c k n o w l e d g e m e n tT h i sw o r kw a ss u p p o r t e db yK o r e aI n s t i t u t eo fI n d u s t r i a lT e c h n o l o g ya n dC w a n g j uM e t r o p o l i t a nC i t yt h r o u g h“T h eA d v a n c e dM a t e r i a l sa n dC o m p o n e n t sI n d u s t r yD e v e l o p m e n tP r o g r a m ”【2 3【4R E F E R E N C E SM i c r o s t r u c t u r ea n dP r o p e r t i e so fA l u m i n u mA l l q y sT h eJ a p a nI n s t o fL i g h tM e t a l s ,1 9 9 1 2 3 3 G K S i g w o r t h :A F ST r a I I S 1 9 8 3 9 1 。7 J E G r u z l e s k ia n dB e r n a r dM C l o s s e t :A F S 1 9 9 0 1 3W G h l k i n g t o n :D i eC a s t i n gD e f e c t s N A D C A1 9 9 7 万方数据Thin-Wall Aluminum Die-Casting Technology forThin-Wall Aluminum Die-Casting Technology forDevelopment of Notebook Computer HousingDevelopment of Notebook Computer Housing作者:Chang-Seog Kang, Jae-Ik Cho, Chang-Yeol Jeong, Se-Weon Choi, Young-Chan Kim作者单位:Korea Institute of Industrial Technology, Gwangju, Korea刊名:材料科学技术学报(英文版)英文刊名:JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY年,卷(期):2008,24(1)引用次数:0次 参考文献(4条)参考文献(4条)1.Microstructure and Properties of Aluminum Alloys 19912.G K Sigworth 查看详情 19833.J E Gruzleski.Bernard M Closset 查看详情 19904.W G Walkington Die Casting Defects 1997 相似文献(3条)相似文献(3条)1.期刊论文 Young-Chan Kim.Chang-Seog Kang.Jae-Ik Cho.Chang-Yeol Jeong.Se-Weon Choi.Sung-Kil Hong Die Casting Mold Design of the Thin-walled Aluminum Case by Computational Solidification Simulation -材料科学技术学报(英文版)2008,24(3) Recently, demand for the lightweight alloy in electric/electronic housings has been greatly increased. However, among thelightweight alloys, aluminum alloy thin-walled die casting is problematic because it is quite difficult to achieve sufficientfluidity and feedability to fill the thin cavity as the wall thickness becomes less than 1 mm. Therefore, in this study, thin-walleddie casting of aluminum (Al-Si-Cu alloy: ALDC 12) in size of notebook computer housing and thickness of 0.8 mm was investigated bysolidification simulation (MAGMA soft) and actual casting experiment (Buhler Evolution B 53D). Three different types of gatingdesign, finger, tangential and split type with 6 vertical runners, were simulated and the results showed that sound thin-walled diecasting was possible with tangential and split type gating design because those gates allowed aluminum melt to flow into the thincavity uniformly and split type gating system was preferable gating design comparing to tangential type gating system at the point ofview of soundness of casting and distortion generated after solidification. Also, the solidification simulation agreed well with theactual die-casting and the casting showed no casting defects and distortion.2.外文期刊 Chang-Seog Kang.Jae-Ik Cho.Chang-Yeol Jeong Thin-Wall Aluminum Die-Casting Technology forDevelopment of Notebook Computer Housing Silicon-based aluminum casting alloys are known to be one of the most widely used alloy systems mainly due to their superiorcasting characteristics and unique combination of mechanical and physical properties.However,manufacturing of thin-walled aluminumdie-casting components,less than 1.0 mm in thickness,is generally known to be very difficult task to achieve aluminum casting alloyswith high fluidity.Therefore,in this study,the optimal die-casting conditions for producing 297
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