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How to use die casting simulation for cost reduction

by Stefano Polli November 18, 2016

Simulation Die Casting

Die casting simulation software is a product developed in the past few years thanks to the technology innovation that has allowed a higher computing power and innovative numerical algorithms. These software allow to approximate with a good precision the behaviour of material fluid inside the mould cavity, adding the chance of a thermo-fluid dynamic analysis of the mould. This kind of analysis is called CFD simulation (Computational Fluid Dynamics).

In this post we are going to look at

  • the benefits of die casting simulation
  • avoiding non-compliant products creation
  • avoiding material waste
  • saving time avoiding empirical tests

Obtain cost reduction through die casting simulation

The benefits of die casting simulation

The simulation is defined by boundary conditions (BC). In high pressure die casting simulation it is possible to modify the parameters of different variables such as injection curves and mould temperature. This activity allows the simulation specialist to discriminate, since the very first phases, the optimal machine parameters to be used during mass production phase, such as the piston stroke.

The simulation process reduces the time required for the machine settings in the product start-up phase, with important savings in terms of time and resources.

Regarding the mould temperature, the software allows the identifation of cold laps and hot spots, and to simulate temperature exchanges during the solidification phase and the mould opening. In this phase it is also necessary to start with the simulation as all the numerical steps are fundamental to help the specialist identifying the best mould design parameters from the very beginning, leading to cost reduction and enhancing the entire process.

Die casting simulation technologies allow to modify both the product design in the start-up phase, and the ongoing process performances. The simulation software can help the specialist analysing real time data to  identify critical points in a mould already in use.

Therefore simulation software are useful both in the planning phase and in the mass production phase: die casting is a technology that has existed for a long time, so it is a matter of combining daily work and experience in the field to offer customers the best quality in the shortest time. Of course the simulation helps to understand the process, but it does not substitute experience and know-how.

The aim of die casting simulation software is to carry out a numerical analysis to avoid material and time waste.

Avoiding non-compliant products creation

The casted product can be non-compliant for different defects which now can be identified before production thanks to the simulation technologies. A proactive approach can anticipate problems such as flow marks and blisters, cold laps, porosity, shrinkage porosity, lakes, and shot to shot inconsistency. Simulation allows to identify the correct equilibrium between speed and temperature and the best geometry of overflows and runner, to avoid the defects in hot chamber hpdc. These activities can anticipate many issues that can appear during production, and avoid undesired events.

Avoiding material waste

In terms of waste of materials it is necessary to define the concept of foundry yield: foundry yield is the ratio, in terms of weight, between processed raw material and final product. It is an important KPI because the injection moulding process uses more raw material than the amount  used for the final product. In the mould the casting is composed by scrap volume. These components, like overflows and runner, are not part of the product itself: the optimization of the correlation between scrap material and material that compose the item allows sure economic savings, reducing runner and overflows dimensions thanks to virtual proofs obtained with the simulation.

Saving time avoiding empirical tests

As described above simulation leads to significant important costs saving during production activities. In addition, the use of simulation software can help companies  cutting costs and reducing sampling phase as it allows to work on different variables before the production.

Die casting simulation software deal with wider subjects than traditional methods, generating a direct saving and, indirectly, allowing to work on new variables that can extend knowledge, and meet the customers’ expectations. The work that has been done so far opens other ways to help the customers  reaching their business goals.

Bruschi engineers are able to monitor and optimize each die casting process phase, to ensure the quality and conformity of the final product and to support your designer’s inventiveness to develop innovative and creative solutions together.

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