Experimental Verification and Accuracy Improvement of Gas Entrapment and Shrinkage Porosity Simulation in High Pressure Die Casting Process

Abstract

In recent years, computer simulation, that is molten metal flow and solidification analysis, has become very important tool for optimal casting and casting plan design. The analysis accuracy was, however, insufficient because of complicate phenomena and difficulty of experiments especially in high pressure die casting process. In this study, effects of various analysis conditions in simple aluminum sand casting were investigated by existing experiments. And subsequently, in actual high pressure die casting experiments for measurement of molten metal pressure, air-pressure, solidification and casting defects especially gas entrapment and shrinkage porosity, computer simulation results of air-pressure, solidification, and those defects were verified.