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3D Printing and Additive Manufacturing
Article . 2023 . Peer-reviewed
License: Mary Ann Liebert TDM
Data sources: Crossref
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Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Authors: Vladislav Andronov; Libor Beránek; Jan Zajíc; Pavel Šotka; Martin Bock;

Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Abstract

Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (∼270 × 270 × 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the ŠKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in ŠKODA AUTO production also decreased.

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
4
Top 10%
Average
Average
Green