A second iteration solved this problem by providing additional venting in the critical (marked) region of the casting.
In the final step, the process parameters and especially the shot curve characteristics for the selected gating layout needed to be determined. In another virtual DoE, MAGMASOFT® was used to determine a second phase velocity that guarantees the lowest possible gate velocities to reduce air entrapment and increase material integrity, while making sure that the melt temperature does not drop below a critical value to avoid misruns. The only variable investigated was the second phase velocity, which was varied between 3.5 and 4 m/s in 0.1 m/s steps.
The virtual DoE confirmed that even the lowest evaluated second phase velocity is sufficient to prevent misruns due to low melt temperatures. The first test production was conducted on a vacuum-assisted 1600 ton high pressure die casting machine. It was directly possible to produce high integrity castings, as was confirmed by x-ray inspection. Subsequent welding tests proved the low gas content of the casting as predicted by MAGMASOFT®, and made it possible to start series production after just one sampling run. The comprehensive and rigorous use of MAGMASOFT® and the MAGMA APPROACH shortened the development and validation process of the high integrity crossbeam significantly. The necessary simulation effort was minimized by a systematic development methodology. Efficient simulations revealed solutions tailored to the relevant question of each specific development stage. This way, the whole product development process was shortened, and substantial costs due to tooling modifications as well as multiple sampling runs were avoided.
Courtesy of NingBo HuiWang Casting Mould Industrial Co., Ltd.