Abstract
In the context of die casting, computer modelling facilitates the design and manufacturing of parts that often have very complex configurations. The technology offers to the user more wholesome and rapid solutions to die casting problems. When properly applied, it can help to reduce production costs through design and process optimization, and shorten product development cycle time. This paper focuses on modelling the two main aspects of die casting: turbulent metal flow and nonisothermal solidification. Modelling of these two phenomena is undertaken by means of the finite element method (FEM). Flow and solidification patterns are generated from 3D finite element mesh representations of the components being analyzed. The information developed can then be used by the die caster to evaluate and optimize cavity design, predict potential defects in the castings, and formulate manufacturing requirements. Theoretical aspects related to the CASTFILL filling model and CASTSOL solidification model are outlined and examples of flow and solidification simulations of die castings in zinc and aluminum alloys are given.
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