Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy

Simulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is t...

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Autores: Anglada Izaguirre, Eva María, Boto Sánchez, Fernando, García de Cortazar Aguirrezabal, Maider, Garmendia Azurmendi, Ignacio
Formato: artículo
Fecha de publicación:2021
País:España
Recursos:Universidad del País Vasco
Repositorio:Addi. Archivo Digital para la Docencia y la Investigación
OAI Identifier:oai:addi.ehu.eus:10810/54221
Acesso em linha:http://hdl.handle.net/10810/54221
Access Level:acceso abierto
Palavra-chave:simulation
modeling
FEM
metamodel
gradient boosting
die casting
aluminum
HPDC
metal casting
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spelling Metamodels’ Development for High Pressure Die Casting of Aluminum AlloyAnglada Izaguirre, Eva MaríaBoto Sánchez, FernandoGarcía de Cortazar Aguirrezabal, MaiderGarmendia Azurmendi, IgnaciosimulationmodelingFEMmetamodelgradient boostingdie castingaluminumHPDCmetal castingSimulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is the long calculation time. In order to apply optimization strategies in the design process or to implement online predictive systems, faster models are required. One solution is the use of surrogate models, also called metamodels or grey-box models. The novelty of the work presented here lies in the development of several metamodels for the HPDC process. These metamodels are based on a gradient boosting regressor technique and derived from a physics-based finite element model. The results show that the developed metamodels are able to predict with high accuracy the secondary dendrite arm spacing (SDAS) of the cast parts and, with good accuracy, the misrun risk and the shrinkage level. Results obtained in the predictions of microporosity and macroporosity, eutectic percentage, and grain density were less accurate. The metamodels were very fast (less than 1 s); therefore, they can be used for optimization activities or be integrated into online prediction systems for the HPDC industry. The case study corresponds to several parts of aluminum cast alloys, used in the automotive industry, manufactured by high-pressure die casting in a multicavity mold.This work was supported by projects OASIS and SMAPRO. The OASIS project has received funding from the European Union’s Horizon 2020 Research and Innovation Programme under Grant Agreement No 814581. The SMAPRO project has received funding from the Basque Government under the ELKARTEK Program (KK-2017/00021).MDPI2021202120212021info:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10810/54221reponame:Addi. Archivo Digital para la Docencia y la Investigacióninstname:Universidad del País VascoInglésinfo:eu-repo/grantAgreement/EC/H2020/814581https://www.mdpi.com/2075-4701/11/11/1747/htminfo:eu-repo/semantics/openAccesshttp://creativecommons.org/licenses/by/3.0/es/2021 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).oai:addi.ehu.eus:10810/542212026-06-18T09:23:17Z
dc.title.none.fl_str_mv Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
title Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
spellingShingle Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
Anglada Izaguirre, Eva María
simulation
modeling
FEM
metamodel
gradient boosting
die casting
aluminum
HPDC
metal casting
title_short Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
title_full Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
title_fullStr Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
title_full_unstemmed Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
title_sort Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
dc.creator.none.fl_str_mv Anglada Izaguirre, Eva María
Boto Sánchez, Fernando
García de Cortazar Aguirrezabal, Maider
Garmendia Azurmendi, Ignacio
author Anglada Izaguirre, Eva María
author_facet Anglada Izaguirre, Eva María
Boto Sánchez, Fernando
García de Cortazar Aguirrezabal, Maider
Garmendia Azurmendi, Ignacio
author_role author
author2 Boto Sánchez, Fernando
García de Cortazar Aguirrezabal, Maider
Garmendia Azurmendi, Ignacio
author2_role author
author
author
dc.subject.none.fl_str_mv simulation
modeling
FEM
metamodel
gradient boosting
die casting
aluminum
HPDC
metal casting
topic simulation
modeling
FEM
metamodel
gradient boosting
die casting
aluminum
HPDC
metal casting
description Simulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is the long calculation time. In order to apply optimization strategies in the design process or to implement online predictive systems, faster models are required. One solution is the use of surrogate models, also called metamodels or grey-box models. The novelty of the work presented here lies in the development of several metamodels for the HPDC process. These metamodels are based on a gradient boosting regressor technique and derived from a physics-based finite element model. The results show that the developed metamodels are able to predict with high accuracy the secondary dendrite arm spacing (SDAS) of the cast parts and, with good accuracy, the misrun risk and the shrinkage level. Results obtained in the predictions of microporosity and macroporosity, eutectic percentage, and grain density were less accurate. The metamodels were very fast (less than 1 s); therefore, they can be used for optimization activities or be integrated into online prediction systems for the HPDC industry. The case study corresponds to several parts of aluminum cast alloys, used in the automotive industry, manufactured by high-pressure die casting in a multicavity mold.
publishDate 2021
dc.date.none.fl_str_mv 2021
2021
2021
2021
dc.type.none.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv http://hdl.handle.net/10810/54221
url http://hdl.handle.net/10810/54221
dc.language.none.fl_str_mv Inglés
language_invalid_str_mv Inglés
dc.relation.none.fl_str_mv info:eu-repo/grantAgreement/EC/H2020/814581
https://www.mdpi.com/2075-4701/11/11/1747/htm
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
http://creativecommons.org/licenses/by/3.0/es/
eu_rights_str_mv openAccess
rights_invalid_str_mv http://creativecommons.org/licenses/by/3.0/es/
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv MDPI
publisher.none.fl_str_mv MDPI
dc.source.none.fl_str_mv reponame:Addi. Archivo Digital para la Docencia y la Investigación
instname:Universidad del País Vasco
instname_str Universidad del País Vasco
reponame_str Addi. Archivo Digital para la Docencia y la Investigación
collection Addi. Archivo Digital para la Docencia y la Investigación
repository.name.fl_str_mv
repository.mail.fl_str_mv
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score 15.301603

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