Runner system design and analysis in simulation of runner system for die casting

Pressure Die Casting offers cost savings due to its near net- to net shaping capabilities, and its smooth surface finish. Turning Pressure Die Casting for its ability to produce small, complexshape, high volume parts, the automotive industry consume parts by the millions. In a casting process, which is characterized by topologically-complex metal/air interfaces having high density ratios and high surface tension, how to model the interfacial flow in kinematically and dynamically is a very important task. This work presents an enhancement of the current gating and runner system design methodologies based on a better understanding of the physics and mathematics of the die casing process. Accurate values of critical parameters involved in the die casting design process such as filling time and freezing time are calculated to allow more knowledgeable decision making during the design stage. As a contribution to study a theory of foundry simulation software the mathematical algorithm and physical algorithm compared in this thesis. A design scenarios were proposed and it supported by well known simulation applications for better understanding. Keywords: Runner system, Gating system, Computational modeling.