Experimental Verification and Accuracy Improvement of Inclusion and Shrinkage Defect Simulation in Die Casting Process

Abstract

  In recent years, molten metal flow and solidification analysis by computer simulation is becoming a very important tool for optimal casting and casting plan design. The analysis accuracy is, however, insufficient because of complicate phenomenon and the need for difficult experiments especially in the die-casting process. In this work, the effects of various analysis conditions in simple aluminum sand casting were investigated using existing experiment results. In addition, actual die-casting experiments to measure molten metal pressure, air-pressure, solidification, and casting defects especially inclusion and shrinkage defects were conducted. The results for air-pressure, solidification, and casting defects showed good agreement with computer simulation results.