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High Pressure Die Casting

Of the many different metal casting techniques, high pressure die casting presents some of the biggest challenges for any casting simulation software. The parts being filled often have very thin walls, so that the number of computational cells must be large in order to suitably resolve the geometry with a mesh. What's more, the metal enters the die cavity under high pressure and at great speeds. The resulting jetting and splashing of the metal throughout the die cavity can lead to defects such as porosity (caused by entrained air) or folds and inclusions (caused when metal reaches an area of the part and begins to cool before the part fills completely).

Simulation of a front Corvette cover, colored by velocity
Simulation of a front Corvette cover, colored by velocity. Results courtesy of C & H Diecasting.

FLOW-3D Cast has several features that substantially improve the accuracy of a die filling simulation, and enable the user to better understand the filling process, including its highly-accurate TruVOF algorithm for tracking moving metal fronts and the FAVOR™ method to accurately represent the complex geometries typically involved in high pressure die casting. Plus, FLOW-3D Cast has numerous models for detecting areas of defects like entrained air, microporosity and fold and inclusions.

Related links:

Watch an On-Demand Webinar: Simulating Aluminum HPDC using FLOW-3D Cast

News from BUHLER: Casting Simulations Help Start Production Faster

Download the FLOW-3D Cast HPDC brochure

Optimization of a Die Cast Vacuum System

Request an HPDC applications demo CD
Making the Switch: Improving High Pressure Die Casting Designs