Optimization of Die Lubricant Application

Kyler M Blowers, Purdue University

Abstract

In high pressure die casting, it is necessary to apply a lubricant to the surface of the die in order to prevent soldering and decrease the cycle time of the casting process. The traditional approach uses a continuous spraying method to apply the lubricant; this can be wasteful. The purpose of this study was to examine the ability of a pulse spray application process to apply die lubricant onto the die surface. A previous study at Purdue University concluded that the pulsed spray method of die lubricant application could result in a significant reduction of the amount of spray runoff and consumption of die lubricant, leading to large cost reductions. The study examined the cooling rates and the resulting temperature differences for different spray pressures and frequencies. After spraying, the affected area of the surface was examined, and the number of particles and coverage area of the particles were measured. The parameters adjusted for this study were the spray pressure, spray duration, and the surface temperature of the hot plate. It was found that a spray pressure of 20 psi does not apply lubricant effectively at 400°C at one, two, or four seconds of spray. At 400°C, it is necessary to have a longer spray duration to apply die lubricant with a spray pressure of 20 psi. It was also concluded that higher pressure and longer spray duration result in a larger affected area of the spray. The research concluded that there is a possible optimal temperature window to apply die lubricant. Further research is necessary to find this temperature window.

Degree

M.S.

Advisors

Han, Purdue University.

Subject Area

Mechanical engineering

COinS