APPLICATION OF COMPUTER CONTROL SYSTEMS IN THE HIGH-PRESSURE DIE CASTING PROCESS OF ALUMINUM ALLOYS ON MODERNIZED EQUIPMENT
DOI:
https://doi.org/10.34185/1991-7848.2026.01.13Keywords:
high-pressure die casting, aluminum alloys, computer-based control, adaptive system, defects, modernization, productivityAbstract
The article addresses the implementation of computer-based control systems in the high-pressure die casting process of aluminum alloys under conditions of equipment modernization. The necessity of ensuring high stability of technological parameters – melt velocity, compaction pressure, and mold temperature – under dynamic operational conditions is emphasized. The study presents a control architecture based on a two-level system: the upper level features a fanless industrial panel PC for visual supervision, while the lower level employs a programmable logic controller (Simatic S7-1200) for real-time signal processing and control of casting phases. The experiments were conducted on a renewed casting line equipped with adaptive control algorithms that monitor dynamic parameters every 10 milliseconds. The system enables precise coordination of the melt injection phase, cavity filling, and final compaction, minimizing hydraulic shock and improving mold filling uniformity. Data visualization modules capture casting temperature, piston velocity (up to 7 m/s), and pressure fluctuations during solidification, allowing predictive adjustments and optimization of process phases without operator intervention. The research results confirm a reduction in cycle time by 10–12%, energy consumption per 1,000 units by nearly 10%, and the share of defective castings (due to porosity or shrinkage cavities) by more than 50%. It is demonstrated that maintaining mold temperature within the range of 220–235 °C is critical for defect-free casting, and deviation from this range increases the occurrence of misruns and shrinkage defects. The proposed control system adapts in real time to alloy transitions and changes in mold geometry, supporting more robust, energy-efficient, and quality-stable casting operations. The integration of computer control technologies into die casting contributes to the advancement of digital manufacturing and supports the broader goal of increasing productivity and product reliability in the foundry industry.
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