Molding system design and its simulation analyse in high pressure die casting

During centuries, casting technology has played an important role in mankind history. At the first ages arrow and spear heads made of reduced minerals and also at modern ages various tools that we use in everyday life are all produced with casting technology. The increasing needs of the society resulted new demands on casting technology which is one of the most important methods of shaping technologies. Especially demands of low-priced pieces with high-quality and zero-mistake lead the development of this tecnology and his sub-branches. Production with high pressure die casting which is one of the most important methods of casting technologies has taken a major place in industry especially automotive sub-industry, despite its high bench and tool costs. However lots of company had to retire from market due to low-cost / high-quality problems. Improper tool desings gives serious economical damages to companies which cant recover their cost of investment. Beside all these, for tools produced with the experience and trial and error, the production period is too long and it is hard to obtain optimum results. Aproximately for 10 years, designs are made and analized via computer with aid of casting simulation software and by experience which is mentioned before, the results of the simulations are revised in order to get the optimum design solution. By these means, possible changes and errors can be corrected before production on the computer software and there wont be any need to correct the tool after production. In this study, two each 2 and 4 cativy tool design of a flange which will be produced with high pressure die casting from Zamak alloy; was investigated with simulation software and optimum results were obtained. The results which are between different cavity tools and same cavity tools were compared. Keywords: High Pressure Die Casting (HPDC), Simulation, Part Design, Zamak