Design of a metal mould for casting brake and clutch levers for a suzuki AX-100 motorbike

Abstract

The aim of the work presented was the design of a metal mould for gravity die casting to obtain brake and clutch handles of aluminium alloys for Suzuki AX-100 motorbike. The maximum stresses to which the part is subjected were determined and evaluated by the finite element method, considering the composition of the existing raw materials, highlighting that the part obtained meets the strength requirements. The results of the simulations showed that the strength was sufficient, and so the design of the metal mould was started. For its design, an established methodology was used, with the Fourier-Kirchhoff models for the thermal regime, resulting in its dimensions. In turn, both filling and solidification were simulated by means of casting software, predicting the thermodynamic behavior and the transient phenomena of the fluid during the pouring process. Positive values were obtained for microporosity, Niyama criterion, flow velocity and solid evolution. The results allowed us to ensure that both the design and the operation of the mould guarantee the production of productive and defect-free handles.