Development and Validation using Casting Simulation of a Multi-point Remote Monitoring System for High-Pressure Die-Casting (HPDC) Mold Cavity

This research presents the design and implementation process of a remote monitoring system for temperature and force-induced pressure measurements in the mold cavity of high-pressure die casting (HPDC). A K-type thermocouple sensor was chosen to gauge the aggressive environment inside the mold cavity. An ejector pin was adapted for the installation of this sensor, collecting data which was then visualized as a real-time graph. To evaluate the accuracy and reliability of temperature data collected from multiple points, this study conducted measurements at five specific locations. By strategically positioning sensors at various desired locations, this study enabled detailed temperature monitoring, allowing for the observation of localized temperature variations and potential issues arising from specific points. The rationality of the obtained data was cross verified using finite difference method (FDM) casting simulation as a reverse engineering method. Additionally, this research outlines a method for utilizing the collected data to identify and predict defects in the casting process. By analyzing temperature and pressure data patterns, the system can detect anomalies indicative of potential defects, thereby aiming to reduce defect rates and enhance the quality of the manufactured products. The proposed system proficiently measures and monitors the temperature and pressure within the mold, detecting any anomalies in the casting process, and applying this data to improve overall manufacturing quality.