Thermo-Mechanical Optimization of Die Casting Molds Using Topology Optimization and Numerical Simulations

Area of Science:

• Manufacturing Engineering
• Materials Science
• Computational Mechanics

Background:

• Conventional die casting mold cooling channels suffer from reduced thermal efficiency due to dirt, limescale, and corrosion.
• These issues lead to prolonged cooling times, non-uniform cooling, and potential casting defects.
• Existing methods struggle to maintain optimal thermal performance and structural integrity during high-load casting processes.

Purpose of the Study:

• To introduce Topology Optimization as a novel method for designing superior cooling structures in die casting molds.
• To enhance thermal efficiency and ensure structural integrity by replacing traditional cooling channels.
• To minimize casting defects and improve overall manufacturing process performance.

Main Methods:

• Designing novel cooling structures using Topology Optimization, incorporating Discrete and Gaussian boundary conditions.
• Employing Structural Topology Optimization to guarantee mold integrity under high operational loads.
• Conducting numerical analysis to compare the performance of optimized channels against conventional designs.

Main Results:

• Optimized cooling structures demonstrated superior thermal performance compared to conventional channels.
• Discrete and Gaussian boundary conditions significantly enhanced thermal efficiency.
• Conformal cooling and minimized temperature gradients were achieved, reducing shrinkage porosity and other casting defects.

Conclusions:

• Topology Optimization is an effective strategy for overcoming the limitations of traditional die casting mold cooling systems.
• The proposed method offers significant improvements in thermal management, structural stability, and casting quality.
• This approach has broad implications for advanced manufacturing processes utilizing permanent molds.