Optimizing High Pressure Die Casting of a Front Cover Dual Cavity Die

FORD was producing front covers using high pressure die casting in aluminum alloy using a single cavity die. Due to high production requirements they needed to become more efficient in the production of their front covers by creating two at a go using a dual cavity die, while maintaining the existing quality level of their front cover. This meant that they needed to attain a filling behavior that was more or less identical to that of a single cavity die.

This study was carried out by a third party, who with the help of MAGMAhpdc (the HPDC module from MAGMASoft) was able to verify the filling behavior of the single cavity die with respect to the aluminum alloy filling velocity, its direction and temperature. Using that data the simulation engineers were able to build a multi-objective optimization method model using MAGMAfrontier and MAGMAhpdc. This allowed them to identify the best gating system configuration, taking into consideration the shape and sections, that would guarantee a suitable temperature and velocity of the fluid or moving metal in the filling phase and that would ensure the absence of gas porosity in the casting.

The simulated optimized configuration was obtained using the MAGMAfrontier optimization tool and was then compared to the simulated configuration of the single die cavity in order to validate the new casting system. Before selecting the final positioning of two die parts, other possible solutions were simulated (without optimization) and investigated to find the best positioning for the parts, in view of next step which was the optimization procedure. The final optimized version reflects a gating optimization with the two parts of the die fixed in a specific location.

The Benefits derived from High Pressure Die Casting Simulation and Multi-Objective Optimization

The HPDC simulation provided Ford with the necessary details to modify the geometry of the gating system to optimize it for the desired velocity flow. To summarize the benefits derived from this project, the new design of the dual-cavity die allowed Ford to:

  • reduce the number of prototypes built to a single one, thus going into production much sooner
  • reduce their production times since they were now able to produce two front covers with a single die
  • save time and money thanks to the reduced sampling time and the reduced production time while maintaining the same quality standards for their customer base

How can EnginSoft help you reduce your high pressure die casting innovation costs?

HPDC simulation can also help you modify your current designs to reduce the possibility of gas porosity in the casting. This case study was provided courtesy of MAGMASoft and whereas this particular case study was not carried out by EnginSoft engineers, our engineers are very knowledgeable when it comes to the die casting requirements of the automotive industry. Contact our experts to let us know what your specific needs are. We have experienced engineers standing by who will quickly evaluate whether your project could benefit from HPDC simulation and MAGMASoft in particular.

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