Abstract
A well-designed gating system for pressure die casting has always been of great importance to achieve good quality castings. However, the cooling system employed in the die and its position has found to have a significant impact on the generation of stresses in the die. High stress concentrations contribute to the erosion of cavity surface thereby affecting the tool life and casting quality. The objective of this research work is to design a die and to analyse the effect of positioning of the cooling channels on the generation of stresses on the cavity surface. In this study, a runner gate system is designed for an ADC 12 aluminium alloy component that is to be cast on a Cold Chamber High Pressure Die Casting (HPDC) machine. Stress analysis and optimization of the cooling channel positionof the die is carried out using ANSYS Workbench. Flow simulation of the optimized design is carried using MAGMA software to understand the effect of cooling channel position on the flow characteristics. The results demonstrate the impact of cooling channel position on the stresses generated in the die and prove to be valuable in designing the die. Defect inspection and testing of porosity is carried out on the castings produced with the optimized design in operation to check if they are acceptable.
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