Process Simulation
The first step in the journey of producing an efficient, productive Die Casting die is to specify and calculate the value all the important process conditions required to make castings of the required quality. These include: Cavity Fill Time, Gate Speed, Die Temperature, Metal Temperature, First Phase Plunger Speed, Second Phase Plunger Speed, Cavity Fill Pressure, Intensification Pressure and many others.
The second step is to produce a die layout, with detailed information about the cavity location, gating, runners, overflows, cooling channels, vents and ejection system.
For many dies, this is all that is required to commence die manufacture.
However, for some parts, it is worthwhile to go one step further and simulate the casting process using specialised animation software.
This enables you to view the flow of the metal into the cavity, to see temperature profiles and to warn of potential problem spots in the casting.
From this information, you might decide to change the position of the gates, or add overflows, or even change the design of the part itself.
When the changes have been made, the simulation can be run again with the new data, to see if an improvement has been made. This process can be repeated until the best compromise is found.
We can supply simulation to your die design as a service to our customers on a case by case basis. To find out more, contact us by email today.