Computer aided engineering (CAE) simulation for the design optimization of gate system on high pressure die casting (HPDC) process

In present casting industries, product development paradigm is shifting from traditional trial-and-error to proof-of-concept based on CAE -enabled simulation. Due to the high velocity of the dynamic behavior of the casting system in working conditions, aluminum die casting is a very complex process in which flow momentum is a critical issue in the mold filling process. In the new production development paradigm, CAE simulation plays an important role because it models the entire casting process and reveals the dynamic behavior of the casting system. In this research, CAE simulation was performed by using the simulation software (AnyCasting) in order to optimize the gate and runner design of an automobile part (Oil Pan_BR2E) which is well known and complicated to achieve a good casting layout. Filling analysis was used to find out the size and location of the gate and proper runner system design. By the modification of the gate and runner system and the configuration of overflows, internal porosities caused by air entrapments were predicted and reduced remarkably. With the solidification analysis, internal porosities caused by the solidification shrinkage were also predicted.