Solutions

Die Casting

Simply Profitable: Simulation in High Pressure Die Casting

The path to lower costs begins with the systematic reduction and elimination of costly casting trials and tooling modifications prior to production. Less scrap, reduced rework and fewer customer rejects all improve your bottom line. Reduced costs give you the edge over your competition.


Desirable die casting processes are characterized by casting conditions that avoid gas inclusions, porosity and cold laps but at the same time provide optimal filling characteristics and short cycle times. Economic production aims at an optimum die temperature control, a long die life, small cycle material amounts and perfectly set machine parameters. Using casting process simulation, die casters gain a deeper understanding of their processes and can adjust die design, casting parameters and runner design in such ways that castings of optimal quality can be produced in economical and robust manufacturing processes.


Simulation of turbulence formation and resulting gas inclusions with the MAGMAhpdc module

Understanding and optimizing processes through simulation comprises:

 

  • Realistic and detailed mapping of all process steps
  • Optimization of the filling process and the cooling of the melt in the shot sleeve
  • Reduction of die costs by evaluating the die design regarding heat-checking and lifetime
  • Reduction of cycle times through optimization of heating and cooling channels
  • Reduction of quality costs by avoiding casting defects that arrive from cold laps, turbulence, air entrapment, gas porosity, and shrinkage
  • Time savings and a robust layout of ingates, runners and vents, vacuum channels and overflows
  • Early and reliable decisions through quantitative predictions of component or tool properties
  • Reduction of production risks by using a high pressure die casting calculator for the rigging layout
  • Minimization of straightening costs caused by modifying cooling conditions, quenching, trimming and heat treatment

MAGMA5 supports measurement procedure: in this case a 6-point method for the analysis of calculated distortions (left). Die temperatures before and after spraying (right).

With modules like MAGMAhpdc and other task-specific components, MAGMA5 offers extensive possibilities to simulate die casting processes in a realistic and reliable way. Among these are:

 

  • Filling and pouring from pouring ladles and dosing furnaces
  • Filling and cooling in the shot chamber
  • High pressure die casting calculator for the filling of the 1st and 2nd phase, part- and machine-specific
  • Consideration of surface tension, venting and vacuum for the shot
  • Porosity prediction also considering the 3rd phase (intensification)
  • Local squeezing
  • Time- or temperature-controlled heating and cooling circuits
  • Warm-up of dies with all thermal and time-related boundary conditions
  • Local spraying and blowing
  • Residual stresses and distortions in castings during solidification after casting removal, gate and overflow cut off as well as during cooling
  • Die stress, prediction of die life and heat checking
  • Stresses and distortions in castings due to stamping and heat treatment
  • Measurement-based evaluation of part distortion

Mathematically estimated lifetime of a die calculated by the MAGMAdielife extension module compared to the real crack pattern of the die.
Case studies

Two for one

The productivity of the casting of a cover was to be improved. Originally, the part was produced using a single cavity die and fulfille...

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Air porosity reduction

WEG is a major electric motor manufacturer in Brazil with captive iron and aluminum high pressure die casting foundries. The die casting ...

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Publications

Latest Advancements in Modelling and Simulation for High Pressure Die Castings

Innovations and modifications in the techniques of high pressure die casting or tooling are forced by trends in part design, part load a...

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