The evaluation of the filling and solidification simulation specifically considered the temperature distribution, melt velocity and air pressure over the course and at the end of filling the die. Special attention was paid to avoiding cold shuts and porosity. Several experience-based proposals regarding casting positions and gating concepts were generated and prepared for analysis to identify the best solution.įour different start designs were chosen by the ZI-team for detailed analysis. On receipt of the CAD data, a suitable production plan was to be developed using casting process simulation. One example is a high pressure die-cast gear housing produced at ZI in Germany. At ZI in Bergzabern, Germany, the new virtual experimentation capabilities in MAGMASOFT ® were recently used to make a successful comparison of different production alternatives for a gear housing.Įven consistently applying casting process simulation, the increasing complexity of cast parts and the variety of quality requirements make it more and more difficult to come to an early and robust decision regarding the optimal design of dies and molds.
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