A simulation and fabrication works on optimization of high pressure aluminum die casting part

Abstract

High-pressure die casting offers reduced costs due to its small tolerances and smooth surface finish. Casting parts produced are consumed by the automotive industry in millions. In this study, the use of computer aided engineering applications on design of high-pressure die-casting was studied. The influence of casting process steps in die design was studied and analyzed. The casting simulation software was used to improve design and solve problems. By using the simulation software in analyses of die design, the final design was reached in a few hours and thus the design process of pre-production was shortened and mold production was carried out with no revision on die material. Radiographic test was applied on the casting parts and the result shows good correlation between simulations of solidification result data. Also the results proved that the application of squeeze pressure in the intensification phase of high-pressure die casting process could be examined in the casting simulation.