The molding analysis of automobile parts using the die-casting system

The casting defects that are caused by molten metal were cold shut formation, entrapment of air, gas, and inclusion. But the control of casting defects has been based on the experience of the foundry engineers. In this paper, computer simulations have been carried out to analyze the flow of molten metal. The quantitative analyses which proposed effective mold designs were executed. Flow patterns of 0.15-0.16 m/s molten metal in 15 mm thin plate casting were examined to find the optimal parameters for the die-casting process. As the ingate velocity in thin plate castings increased, the cold shot had decreased. The runner shape parameters affected the optimal conditions that were calculated through simple equations and examined using the experimental outputs. The calculated results for automobile valve body mid-plate to control the die-casting process have achieved good agreements with the experimental data in terms of tensile strength and hardness test, and material structure showed satisfactory results. (C) 2007 Elsevier B.V. All rights reserved.