Design Optimization of a Die Casting Mold for Aluminum Alloy Components

The current study has examined the problem of optimizing a mold design used in the casting of aluminum alloy parts. In this case, the primary goals were the improvement of the process quality, reduction of defect formation and increasing the productivity of production. For achieving these goals, a combined approach has been applied including modeling and optimization. Firstly, the mold and the components geometry were created through UG software (Unigraphics NX). The complexity of the geometrical shapes, such as gates, cavities, and cooling systems could be accurately simulated through this process. Subsequently, the simulation of the flow pattern of molten metal filling the mold and solidification processes took place through MAGMASOFT software, which was able to visualize the fluid flow, temperature variation, and solid phase fraction during the whole casting process.

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