Simplified Models for High Pressure Die Casting Simulation

Abstract

The simulation of the High Pressure Die Casting (HPDC) process is a complex type of simulation. The industrial procedure is based on consecutive manufacturing cycles that must be taken into account in the simulation. Moreover the part geometries use to be complex and the alloy is injected at really high velocities. All of that usually implies long calculation times that in complex cases can lead to several days. Sometimes, the circumstances require to have available a fast solution despite involve a loss of accuracy. The work presented hereafter discusses different possibilities to simplify the HPDC simulation models together with their benefits and drawbacks. The simplified simulation models have been validated against a detailed 3D simulation model, previously correlated with experimental results. The comparative, shows that the use of simplified models may be a solution that makes possible a big reduction in calculation times maintaining a reasonable level of accuracy.