advances in numerical modeling of manufacturing processes

TRANS. INDIAN INST. MET., VOL. 57, NO. 4, AUGUST 2004
Fig. 16: The geometric parameters of the gate and the design values chosen in the optimization.
symmetry, a two-cylinder model was used for
simulation as it reasonably represents the filling
characteristics of the entire block since cross-flow
between cylinders is very less.
The results and comparisons of the simulations are
shown in Fig. 17. In the simulation of the existing
design, the runner system is included while in the
simulation of the new design, a runner system has
not been included. Consequently, in the new design
the metal reaches the gate very fast, whereas in the
existing design the metal reaches the gate only after
0.1 sec. So the comparison plots have been made at
the same times that have elapsed after the metal
reached the ingate. The figures only show the regions
that have been filled with metal.
In all the three figures, we can see that in the case
of the new design the filling is faster than the existing
ingate design case. The bearing areas get filled much
faster and hence there is more time for the thick
sections to solidify and this could lead to reduced
shrinkage defects in the region. The vent region and
the adjoining areas also get filled at almost the same
time and hence there is lesser chance of entrapped
gas porosity in that region in the new design. From
the above comparison it can be seen that the new
ingate design combined with a larger ingate velocity
favors better filling in the bearing and the vent regions.
This will help in the reduction of entrapped gas
porosity during filling and shrinkage porosity during
the solidification stage.
Fig. 17: The fill pattern in the new design (left) and the fill
pattern in the original design (right) 45
4.5 Benefits to Industry
This study provided to the die casting industry a
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