Cold-chamber die casting is the most expensive method of mass producing light metal castings, despite the fact that it is the most widely used. It is also the most widely available. According to Magmasoft, the following considerations must be taken into account in order to achieve a cost-effective lightweight design concept:Since its introduction into the automotive component manufacturing industry, this technology has grown to account for more than half of global production, according to industry estimates. As continuous quality improvement is introduced intoprecision die casting supplierthe zinc die casting manufacturermanufacturing of automotive components, the technology's popularity is expected to continue to increase. DSM, an Italian design studio, discovered during a development project that critical factors must be taken into consideration in order to realize a cost-effective lightweight construction concept while also ensuring process reliability for an aluminum die casting with high functional performance requirements in the automotive sector. In the image gallery, you can see a great representation of what I'm talking about in Figure 1, which is the best illustration of what I'm talking about.
The first step hasdie casting moldbeen taken in the form of a preliminary virtual investigation, which has been launched before anything else.
When it comes to structural strength, the component in question is a cover with the highest level of operational reliability available. It also includes a hydraulic seal to prevent oil leakage from the engine while it is in operation. It was decided by the Italian engineers to conduct a virtual preliminary study to see how the tool performed during the manufacturing process in order to detect critical problems with the internal integrity of the component at an early stage (see Figure 2 in the photo gallery).
It was discovered through virtual analysis of the initial configuration that several critical issues existed, including the fact that the solidification process did not produce satisfactory results because of isolated shrinkage in areas of the component that must maintain a hydraulic seal while in operation; the fact that the solidification process did not produce satisfactory results because of isolated shrinkage in areas of the component that must maintain a hydraulic seal while in operation; the fact that the solidification process did not produce satisfactory resultsbecause of isolated shrinkage in areas of the component that must maintain a hydraulic seal whileDuring the course ofdie casting servicesthe investigation into various alternative designs for the gating system in order to reduce shrinkage porosity to the absolute minimum level possible while also minimizing trapped air, special attention was paid to the component's heaviest section, which was the most difficult to achieve. On the basis of Figure 3, it can be seen that switching to a four-cavity mold has resulted in lower production costs as well as lower costs of mold tooling maintenance and repair.
Because of the new layout, a significant reduction in the number of critical components for internal integrity thataluminum die casting partswere previously present in the heavy section has been achieved. It was necessary to define an appropriate thermal control system (see Figure 4 of the image gallery) in order to complete the design, which was done after a satisfactory layout (see Figure 1 of this gallery) had been identified. Figure 4 shows the thermal control system definition.
In order to verify a claim or hypothesis, it is necessary to run simulations on the underlyingdata.
Because of the use of these tools in conjunction with the corresponding simulations, it was possible to virtually validate both the dimensioning of cooling lines and the process parameters that were involved in those lines of work in a virtual environment. The results of the experiments showed that the anticipated improvements, which allow for a direct transition from the design phase to the manufacturing phase, had been confirmed, as predicted. This is illustrated in Figures 5 and 6, respectively, to demonstrate the point.
