Enhancing side die resistance to thermal shock in automotive casting: a comparative study of FCD550 and SKD6 materials

Authors

DOI:

https://doi.org/10.15587/1729-4061.2024.306615

Keywords:

thermal shock, die disc car wheel, manufacturing, automotive parts, casting productivity

Abstract

Enhancement of side die resistance to thermal shock in mold disc car applications was achieved by substituting FCD550 material with SKD6 material. The primary issue addressed is the cracking of side dies due to thermal shock induced by an accelerated production process, leading to production halts and failure to meet large customer orders. The study aims to identify a material that can better withstand thermal shock than FCD550, thereby improving the durability of side dies and the overall productivity of the manufacturing process. The research involved direct production experiments, analyzing the materials FCD550 and SKD6, evaluating die characteristics, and assessing finished product attributes before and after material changes. Laboratory tests and machine-setting trials were conducted, varying production processes and assessing the results. The findings indicate that SKD6 is significantly more resistant to thermal shock than FCD550 in mold disc car applications. The study compared the strength of side die materials using data sheets and adjusted setting parameters under existing cooling conditions. Experimentation involved altering the standard temperature from 520 °C–545 °C to 532 °C–538 °C and reducing the soaking time from a minimum of 270–540 seconds to 332 seconds. This reduced soaking time from 69 seconds to 46 seconds and aging time from 190 seconds to 180 seconds, increasing casting productivity from 194,870 pieces/28 days to 213,311 pieces/28 days across seven machines, thereby fulfilling the customer’s requirement of 200,000 pieces/28 days without side die cracks. Durability testing on five product samples according to TSD5605G standards confirmed the quality as meeting customer specifications

Supporting Agency

  • The author would like to acknowledge the funding support to this research from the Center of research and community service Politeknik Negeri Jakarta. The author would like to acknowledgments to Mr. Juhery the funding support to this research from Engineering department PT. PAKO 4-wheel Jakarta.

Author Biographies

Herry Patria, Politeknik Negeri Jakarta

Master's Program in Applied Manufacturing Technology Engineering

Iwan Susanto, Politeknik Negeri Jakarta

Doctor of Materials Science and Engineering, Associate Professor

Master's Program in Applied Manufacturing Technology Engineering

Belyamin Belyamin, Politeknik Negeri Jakarta

Doctor of Energy Conversion, Associate Professor

Master's Program in Applied Manufacturing Technology Engineering

Dianta Mustofa Kamal, Politeknik Negeri Jakarta

Doctor of Energy Conversion, Associate Professor

Master's Program in Applied Manufacturing Technology Engineering

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Enhancing side die resistance to thermal shock in automotive casting: a comparative study of FCD550 and SKD6 materials

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Published

2024-06-28

How to Cite

Patria, H., Susanto, I., Belyamin, B., & Kamal, D. M. (2024). Enhancing side die resistance to thermal shock in automotive casting: a comparative study of FCD550 and SKD6 materials. Eastern-European Journal of Enterprise Technologies, 3(12 (129), 46–55. https://doi.org/10.15587/1729-4061.2024.306615

Issue

Vol. 3 No. 12 (129) (2024): Materials Science

Section

Materials Science

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Copyright (c) 2024 Herry Patria, Iwan Susanto, Belyamin Belyamin, Dianta Mustofa Kamal

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