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.

Model file is available in the tutorial_models folder in the installation directory in Program Files\Altair\2021.1\InspireCast2021.1\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.


  3. Use the mouse and view controls to position the model.

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 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, the 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 Porosity Animation

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


Note:
  • To avoid defects like trapped air, we can optimize the design and use a runner system.


  • To avoid porosity, we will add additional components which act as vents to collect the trapped air.

Open the New Model

  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.


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.

Designate Surfaces as Gates

  1. Click the Casting tab.
  2. On the the Gate icon, click Designate Surfaces as Gates.

  3. Click the predesigned gate.


  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.




Configure High Pressure Parameters

  1. Click the Casting tab.
  2. Click to select the High Pressure icon.
  3. Select By point and enter an Init. Vel. of 0.5 m/s and a 2nd Phase Vel of 2 m/s.


Run Analysis

  1. 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 3.06039 mm.
  5. Click Run.
    Note: Once the simulation calculation is finished, the 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 Last Air Result

Click Last Air under Result Types.


Note: The Last Air option shows where air will become trapped during the filling process. When compared to the previous design, air trapped inside of the casting is almost negligible while there is some air in the vent system and filling system.

Run the Porosity Animation

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


    Note: Compared to the previous design, there isn't any Porosity inside the casting. Instead, it is inside the vent and filling systems.