Theoretical and Experimental Studies of Die Casting Techniques for Small Engine Connecting Rods

A computerized solidification model based on heat transfer theory has been developed for application to die castings to improve their reliability. The model was applied to a small engine connecting rod to investigate the effects of uniform die temperatures, die temperature gradients, insulated coring, melt temperatures, and gate location on solidification patterns. The simulation results indicate that directional solidification cannot be achieved with reasonable die temperature gradients, but can be with a combination of proper gate location and die temperature control. The quality of the connecting rod casting was improved through an instrumentation study of casting variables and by changing gate location and casting procedures as suggested by the solidification model.