“Minimization of Defects by Simulation of High-Pressure Die Casting”

Abstract

Casting simulation helps visualize mold filling and casting solidification; predict related defects like cold shut, shrinkage porosity, and hard spots, and optimize the casting design to achieve the desired quality with high yield. Flow and solidification of molten metals, is however, a very complex phenomenon that is difficult to simulate correctly by conventional computational techniques, especially when the part geometry is intricate and the required inputs ((like thermo-physical properties and heat transfer coefficients) are not available. For industrial applications, we need alternate approaches that are fast, reliable, and user-friendly. It is important to trace the history of such approaches as well as their incorporation into software programs for casting design  and simulation.

Key benefits and best practices, based on studies of industrial cases of casting defect prediction. Current research directions include the integration of basic and advanced simulation techniques, useful for large foundries. It is an effort towards making things run smoothly with efficient utilization of available resources. Optimization is the philosophy of life. When applied to the engineering sector, that too to foundry saves unnecessary wastage of resources. This leads to noticeable savings in terms of time and cost. In this paper, simulation is carried out using Z-Cast simulation software to study various process parameters which minimizes the defects in High Pressure Die-casting (HPDC) components.