The increasing complexity of modern high pressure die castings and the variety of quality requirements call for early-stage robust decision-making on casting process design. Structural components are characterized by complex thin-walled geometries, often combined with thick-walled areas for fastening points. In addition, minimum draft angles as well as the high demands on surface quality pose a particular challenge for the spraying process. From a tooling point of view, a major priority is the prevention of early-stage damages caused by thermal shock due to conventional water-based spraying.
The new options available in MAGMASOFT® 5.4 allow optimizing the spraying process in detail: For example, you can analyze in detail the surface temperature of the die or the wetting of individual tool areas for optimizing the casting quality. In this context, among others, cold laps, porosity or die soldering are considered. Moreover, it is possible to evaluate the distortion of tool components or the lifetime of a die insert.
The following images show the spraying process represented in MAGMASOFT® with individual spray nozzles and spray circuits as well as the spray head movement including the display of the resulting local surface temperatures of the die in the course of the spraying process.