Die casting parameters and simulations for crankcase of automobile using MAGMAsoft

Abstract

Abstract High Pressure Die Casting (HPDC) is popular for manufacturing of high volume and low cost cast components with good quality. In this study, the step by step method of developing a HPDC die is demonstrated for a crank case of two wheeler automobile by evaluating the necessary design parameters of HPDC. The die is designed for Al-Si-Cu alloy as melt. Simulations are done using MAGMAsoft for predicting filling temperature, fill time, solidification, air pressure and entrapment and lastly assessment of cooling arrangement. Minor modifications are carried out to accommodate lesser fill time and reduced air pressure in the die cavity.