Tutorial: High Pressure Die Casting

Set up a high pressure die casting simulation and see how to troubleshoot it.

In this exercise, you will learn how to run an analysis and prevent typical casting defects for the high pressure die casting process. The process must balance the need to fill the mold quickly enough to prevent premature solidification with the need to fill the mold slowly enough to prevent air mixing with the liquid, causing porosity in the finished part.

Model file is available in the tutorial_models folder in the installation directory in Program Files\Altair\2024\InspireCast2024\tutorial_models\handle.x_b.

Import Geometry

  1. Launch Inspire Cast.
  2. Click Open Model on the Files icon and browse to the tutorial model file in the installation directory, or drag-and-drop the file into the modeling window.


Designate a Cast Part

  1. Click the Casting tab.
  2. On the Cast Part icon, click Designate Casting Part.
  3. Click on the cast part.


  4. Use the microdialog options to define the material, alloy, and temperature.

Create an Ingate

  1. Click the Casting tab.
  2. On the Gate icon, click Add/Edit Gate.

  3. Click on the part to create a virtual gate.


  4. Use the microdialog options to define the gate's position, shape, and dimensions.


Create a Mold

  1. Click the Casting tab.
  2. Click the Components icon.
  3. Click the Mold icon.
  4. Define the mold material and temperature as shown.




Configure Basic Setup

  1. Click the Casting tab.
  2. Click the Basic Setup icon.
  3. Select Initial Velocity and enter 35 m/s.

Run Analysis

  1. On the ribbon, click the Casting tab.
  2. On the Analysis icon, click Run Analysis.
  3. Select Run filling analysis and Run solidification analysis.
  4. Enter an average thickness of 1.53019 mm.
  5. Click Run.
    Note: Once the simulation calculation is finished, a green flag will appear on the analyze icon.

    Note: The user can also select the results by clicking View Now under Run History.


Run the Temperature Animation

  1. Click Temperature under Result Types.
  2. Click Play to start the animation.


View the Porosity Result

Click Demolding under Stage, then click Porosity under Result Types.


Note:
  • To avoid defects like trapped air, we can optimize the size, shape, and placement of the inlet. Experiment with the gate's configuration and placement and re-run the analysis to see the difference in the results.
  • Once you know the optimal configuration of the inlet, you can design a filling system for high-pressure casting.

Open the New Model

Use the model provided to run a high-pressure casting analysis.

  1. Click File>Open.
  2. Browse to and select <installation directory>\tutorial_models\handlefull.x_b

Cast Material and Temperature

  1. Click the Casting tab.
  2. On the Cast Part icon, click Designate Casting Part.
  3. Click on the cast parts.


  4. Use the microdialog options to define the material, alloy, and temperature.


Designate Filling System

  1. Click the Casting tab.
  2. On the Cast Part icon, click Designate Filling System.
  3. Click the runner parts.


  4. Right-click and mouse through the check mark to exit, or double-right-click.

Set Gravity Direction

  1. Click the Casting tab.
  2. On the Cast Part icon, click Set Gravity Direction.
  3. Use the microdialog options to rotate, align, or flip the model with respect to the direction of gravity (the z-axis).


  4. Right-click and mouse through the check mark to exit, or double-right-click.

Generate a Mold

  1. Click the Casting tab.
  2. Click the Components icon.
  3. Click the Mold icon.
  4. Use the microdialog options to define the material and temperature.




Generate a Shot Sleeve

  1. Click the Casting tab.
  2. Click the Components icon.
  3. Click the Shot Sleeve icon.
  4. Click the ingate surface on the designated runner system. In the microdialog, set the shot sleeve's diameter to 50 mm and its length to 200 mm. Set the piston's velocity to be 500 mm/s at 0 seconds and 153.32 seconds, and 2500 mm/s at 161.83 seconds and 200 seconds.


Configure High Pressure Parameters

  1. Click the Casting tab.
  2. Click to select the High Pressure icon.
  3. Using Shot Sleeve is selected by default. The Piston velocity control table is already populated with the data you entered in the previous step. Use the default settings for Mass, Piston initial temperature, and Chamber initial temperature, and the other fields. It is not necessary to select Show PQ2 diagram or Compute Clamping Forces.


    Note: The first velocity in the Piston Velocity Control table must move the liquid material slowly enough that the liquid does not mix with the air inside the shot sleeve. Once the air is pushed out of the shot sleeve, the piston velocity can increase.

Run Analysis

  1. Click the Casting tab.
  2. On the Analysis icon, click Run Analysis.
  3. Select Run a filling analysis and Run a solidification analysis.


  4. Enter an average thickness of 3.06039 mm.
  5. Click Run.
    Note: Once the simulation calculation is finished, a green flag will appear on the analyze icon.

    Note: The user can also select the results by clicking View Now under Run History.


Run the Temperature Animation

  1. Click Temperature under Result Types.
  2. Click Play to start the animation.


Run the Flow Front Animation

  1. Click Flow Front under Result Types.
  2. Click Play to start the animation.


    Note: The Flow Front animation shows where air may mix with the liquid material, which can cause porosity in the finished product.

View Last Air Result

Click Last Air under Result Types.


Note: The Last Air option shows where air will become trapped during the filling process. Use this result to help determine where to place overflow compnents to ensure that no air is left in the part.

View the Porosity Result

Click Demolding under Stage, then click Porosity under Result Types.


Note: This result shows where the material is contracting during solidification, which can cause structural weakness.