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 |  موضوع: كتاب Fundamentals of Die Casting Design الإثنين 07 يناير 2013, 4:06 pm | |
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Fundamentals of Die Casting Design
Genick Bar{Meir, Ph. D.
7449 North Washtenaw Ave
Chicago, IL 60645
email:barmeir at gmail dot com
و المحتوى كما يلي :
Contents
GNU Free Documentation License . xi
1. APPLICABILITY AND DEFINITIONS xii
2. VERBATIM COPYING . xiii
3. COPYING IN QUANTITY . xiii
4. MODIFICATIONS . xiv
5. COMBINING DOCUMENTS . xvi
6. COLLECTIONS OF DOCUMENTS xvi
7. AGGREGATION WITH INDEPENDENT WORKS xvi
8. TRANSLATION xvii
9. TERMINATION xvii
10. FUTURE REVISIONS OF THIS LICENSE xvii
ADDENDUM: How to use this License for your documents . xviii
CONTRIBUTORS LIST xix
How to contribute to this book xix
Credits . xix
Steven from artofproblemsolving.com xix
Tousher Yang . xix
Steve Spurgeon xx
Irene Tan . xx
Your name here xx
Typo corrections and other "minor" contributions xx
Prologue For The POTTO Project xxiii
Preface xxiii
Why Volunteer? . xxiv
What Has been So Far . xxv
Prologue For This Book xxix
Version 0.1 January 12, 2009 xxix
pages 213 size 1.5M xxix
Version 0.0.3 October 9, 1999 . xxix
pages 178 size 3.2M xxix
iiiiv CONTENTS
1 Introduction 1
1.1 The Importance of Reducing Production Costs 2
1.2 Designed/Undesigned Scrap/Cost . 4
1.3 Linking the Production Cost to the Product Design . 4
1.4 Historical Background . 5
1.5 Numerical Simulations . 6
1.6 \Integral" Models . 9
1.7 Summary 11
2 Basic Fluid Mechanics 13
2.1 Introduction 13
2.2 What is fluid? Shear stress 14
2.2.1 What is Fluid? . 14
2.2.2 What is Shear Stress? . 14
2.3 Thermodynamics and mechanics concepts 16
2.3.1 Thermodynamics . 16
2.3.2 Basic Definitions . 16
2.3.3 Momentum Equation . 23
2.3.4 Compressible flow . 23
2.3.5 Speed of Sound 23
2.3.6 Choked Flow 25
3 Dimensional Analysis 33
3.0.1 How The Dimensional Analysis Work . 34
3.1 Introduction 35
3.2 The Die Casting Process Stages . 35
3.2.1 Filling the Shot Sleeve 36
3.2.2 Plunger Slow Moving Part 38
3.2.3 Runner system . 41
3.2.4 Die Cavity . 42
3.2.5 Intensification Period . 43
3.3 Special Topics . 43
3.3.1 Is the Flow in Die Casting Turbulent? 43
3.3.2 Dissipation effect on the temperature rise 47
3.3.3 Gravity effects . 47
3.4 Estimates of the time scales in die casting 48
3.4.1 Utilizing semi dimensional analysis for characteristic time 48
3.4.2 The ratios of various time scales . 56
3.5 Similarity applied to Die cavity 58
3.5.1 Governing equations 58
3.5.2 Design of Experiments 61
3.6 Summary of dimensionless numbers 61
3.7 Summary 63
3.8 Questions . 63CONTENTS v
4 Fundamentals of Pipe Flow 65
4.1 Introduction 65
4.2 Universality of the loss coefficients 65
4.3 A simple flow in a straight conduit 66
4.3.1 Examples of the calculations . 68
4.4 Typical Components in the Runner andVent Systems 68
4.4.1 bend 68
4.4.2 Y connection . 69
4.4.3 Expansion/Contraction 69
4.5 Putting it all to Together . 69
4.5.1 Series Connection . 69
4.5.2 Parallel Connection 70
5 Flow in Open Channels 71
5.1 Introduction 71
5.2 Typical diagrams 73
5.3 Hydraulic Jump 73
6 Runner Design 75
6.1 Introduction 75
6.1.1 Backward Design . 75
6.1.2 Connecting runner segments . 76
6.1.3 Resistance . 77
7 pQ2 Diagram Calculations 81
7.1 Introduction 81
7.2 The \common" pQ2 diagram 82
7.3 The validity of the \common" diagram 85
7.3.1 Is the \Common" Model Valid? . 86
7.3.2 Are the Trends Reasonable? . 88
7.3.3 Variations of the Gate area, A3 89
7.4 The reformed pQ2 diagram . 89
7.4.1 The reform model . 90
7.4.2 Examining the solution 92
7.4.3 Poor design effects 105
7.4.4 Transient effects 105
7.5 Design Process . 106
7.6 The Intensification Consideration . 107
7.7 Summary 107
7.8 Questions . 107vi CONTENTS
8 Critical Slow Plunger Velocity 109
8.1 Introduction 109
8.2 The \common" models 110
8.2.1 Garber’s model 110
8.2.2 Brevick’s Model 112
8.2.3 Brevick’s circular model 113
8.2.4 Miller’s square model . 113
8.3 The validity of the \common" models 114
8.3.1 Garber’s model 114
8.3.2 Brevick’s models 114
8.3.3 Miller’s model . 115
8.3.4 EKK’s model (numerical model) . 115
8.4 The Reformed Model . 115
8.4.1 The reformed model 115
8.4.2 Design process . 118
8.5 Summary 118
8.6 Questions . 118
9 Venting System Design 119
9.1 Introduction 119
9.2 The \common" models 120
9.2.1 Early (etc.) model . 120
9.2.2 Miller’s model . 120
9.3 General Discussion . 121
9.4 The Analysis 123
9.5 Results and Discussion 125
9.6 Summary 128
9.7 Questions . 128
10 Density change effects 129
11 Clamping Force Calculations 133
12 Analysis of Die Casting Economy 135
12.1 Introduction 135
12.2 The \common" model, Miller’s approach . 136
12.3 The validity of Miller’s price model 136
12.4 The combined Cost of the Controlled Components . 137
12.5 Die Casting Machine Capital Costs 137
12.6 Operational Cost of the Die Casting Machine 138
12.7 Runner Cost (Scrap Cost) 139
12.8 Start{up and Mold Manufacturing Cost . 141
12.9 Personnel Cost 142
12.10Uncontrolled components 142
12.11Minimizing Cost of Single Operation . 144CONTENTS vii
12.12Introduction to Economics 147
12.12.1Marginal Profits 149
12.13Summary 151
12.14Question 151
A Fanno Flow 153
A.1 Introduction 153
A.2 Fanno Model 154
A.3 Non{Dimensionalization of the Equations 155
A.4 The Mechanics and Why the Flow is Choked? 158
A.5 The Working Equations 159
A.6 Examples of Fanno Flow . 162
A.7 Supersonic Branch . 168
A.8 Maximum Length for the Supersonic Flow 169
A.9 Working Conditions 169
A.9.1 Variations of The Tube Length ( 4DfL ) Effects 169
A.9.2 The Pressure Ratio, PP21 , effects 175
A.9.3 Entrance Mach number, M1, effects . 177
A.10 Practical Examples for Subsonic Flow 185
A.10.1 Subsonic Fanno Flow for Given 4fL
D and Pressure Ratio 185
A.10.2 Subsonic Fanno Flow for a Given M1 and Pressure Ratio 186
A.11 The Approximation of the Fanno Flow by Isothermal Flow . 189
A.12 More Examples of Fanno Flow 190
A.13 The Table for Fanno Flow 191
A.14 Appendix { Reynolds Number Effects 193
B What The Establishment’s Scientists Say 197
B.1 Summary of Referee positions . 198
B.2 Referee 1 (from hand written notes) . 199
B.3 Referee 2 200
B.4 Referee 3 203
C My Relationship with Die Casting Establishment 209
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