Jul 30, 2021

Mold Flow Simulation For Die Casting Mold

When you first get involved in casting, especially die casting, one of the very important steps in the design process is mold flow simulation. But why we do mold flow analysis and what is mold flow simulation?

We will start with these two aspects and introduce the reasons and methods.

High Pressure Die Casting Simulation

The die casting process designer is a complex and empirical creative job. In die casting production, the three main elements are die casting machine, die casting alloy and die casting mold. The die casting process is the organic combination of these three elements and the reasonable choice of settings. Therefore, to die casting process parameters for the correct selection, control, and adjustment, so that a variety of process parameters to meet the needs of die casting production, in order to produce qualified die casting under other conditions of quality.

CAE Technology

Make use of the powerful computing and graphic functions of computers to assist mold design, improve the design accuracy and design reliability, design reasonable mold structure and reasonable pouring system. Numerical simulation of the die casting process by CAE technology, commonly known as computerized mold testing, visualizes the whole process of flow and solidification of metal liquid in the cavity during casting generation and analyzes the factors of defect formation.

Mold Flow Simulation and Analysis

With the continuous development of simulation technology, computer hardware, and software, The needs of the casting market, the numerical simulation of the casting process is to establish the correct mathematical models, and through the appropriate values, use the computer to analyze these models and use them to guide the casting practice in terms of flow, temperature, organization, etc.

The simulation results are observed through post-processing, and the flow and solidification process of the metal fluid in the cavity is animated through multiple angles and profiles to track the view and locate the defective parts inside the casting.

To support our customers in getting the best productivity and part quality, CAMEL always provides flow simulation by designing various kinds of runner layouts. By doing this our T1 success rate is over 96%.

In this preliminary flow simulation, it appears that the outermost feeders are not supplying hot metal directly to problem areas while the center section is filling well. CAMEL adjusted the runner layout as shown below for a successful T1.

Step 1: Eliminate (2) end feeders and make them overflow.

Step 2: Change the feeder angle and gate towards the outer edge of the part.