Friction modeling and analysis of injection process in squeeze casting

An analytic model is presented for quantitatively investigating the impact of friction between the punch and the shot sleeve on dynamic match status during the injection process of squeeze casting, with the ultimate purpose of optimizing machine design and controlling injection process more accurately. By combining lubrication model and friction experiment, the friction characteristics between the punch and the shot sleeve are investigated in four cases of different clearance values. The lubrication model is validated by comparing the calculated and experimental values of the friction coefficient. The friction model of injection process is then established by means of updating incremental boundary conditions iteratively. The temperature and deformation data are collected from laboratory testing and used to compare with the simulation data obtained from both the general model and the proposed friction model. The simulation data from the friction model is approximately in agreement with the experimental data, better than the general model, implying that the proposed analytics model provides more accurate simulation of the friction coefficients.