CAST METAL FLOW ANALYSIS OF INTERMEDIATE FLANGE

Abstract

The production of aluminium alloy die castings has been seeing a continuous increase to answer the strong demand by the automotive industry for higher strength and lighter weight. The die castings for automotives are required of not only high quality as of course but also thin walls and a high dimensional precision, thus it is essential to provide advanced casting technologies for the manufacturing of these castings. The main challenge in die casting is design and manufacturing of die. Integration of design and analysis yields to better results. Die casting is often encountered with many problems, few of such problems are blowholes, improper filling, scratch marks, weld lines, cracks, cold shut, porosity, blisters, ejector pin marks, etc. usually these defects are caused due to improper design of dies, or due to incorrect parameters such as injection pressure, cycle time, cooling circuits and other such parameters n order to eliminate such defects a set of analysis has to be carried to ensure that design and other parameters are safe and efficient. Through analysis is carried to understand how the molten metal behaves inside the dies once it is injected, a clear picture about how the molten metal gets solidified is obtained during analysis. Any defects if present can be studied by analysing the results of analysis. In this paper Adestefan analysis software is used for analysis purpose, the flow of molten metal inside the impression was studied and changes to be made to the design were analysed. Behaviour of molten metal at different stages of time such as temperature variations, pressure variations is analysed.