Optimal Design and Simulation of Die Casted Machine Components for Minimal Failure Rate Using Alternative Die Casting Materials

Author Name : Vimlesh Kumar Ojha, Poonam Chhabra

ABSTRACT

As a fabrication process, die casting is notable for its capacity to manufacture parts with a high degree of uniformity, close design accuracy, and quality surface finishes. Casting includes sensitive process parameters such as selection of materials, process selection, melt temperature, filling time, gating design which must be optimized to reduce the occurrence of casting defects. Initially these parameters are optimized in real casting tryouts which results into the losses of resources. Simulation technology has emerged as a boon to die casting engineers to perform virtual trials, predict casting defects and improve the die design without pouring a single shot. This not only eliminates the cost of die modification and material energy costs, but also provides a better insight into the process and enables exploring more alternative solutions. The presents the optimal design and simulation of die casted machine component (rim) for minimal failure rate using alternative die casting materials using AutoCAST simulation software. The core print design, feeder location and feed path, mold filling and gating design are analyzed and optimized for alternative materials for rim.

Keywords:  Die-casting, Defects, Simulation, AutoCAST, Rim