Christian Kleeberg, MAGMA Engineering Asia-Pacific Pte Ltd, Singapore
1.0 Introduction: Innovations and modifications in the techniques of high pressure die casting or tooling are forced by trends in part design, part load as well as by costs and times for development and manufacturing processes. All current trends require continuous improvement in planning of part performance and production processes. The quality of parts and the efficiency of development and manufacturing processes are primarily depending on the quality and accuracy of the planning process.
Generally, there are two crucial factors that secure the reliability of planning:
- Experiences from past projects that can be used in future projects, and
- Modelling and simulation of processes based on general physical laws.
In high pressure die casting the term ‘modelling’ means the reproduction of the casting process in simulation programs. In this method, the very detailed process flow is specified as a boundary condition in a calculation. The result is the representation of die filling, solidification, formation of microstructure and properties, as well as development of residual stress and distortion in the castings.
As this is the quickest and most cost-effective method to develop a high-value product, die casting modelling and simulation gets more and more important. [...]
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