After deciding the die casting unit, the user inputs the product’s average wall thickness according to the product’s structural characteristics, and MAGMASOFT calculates all process parameters including filling rate, low speed and high speed switching location, high speed, internal gate cross-sectional area, filling time and internal gate speed. The software also recommends best related data such as molding time, molding time and low speed, high speed switching location, high speed and cross-sectional internal gate area. The user can input various parameters based on the factory machine’s actual output, and then the program will produce a database parameter such as the inner gate’s cross-sectional area and inner gate speed.
3. Analysis of gating and discharge systems
3.1 Selection of the gating system
All the pouring possibilities are input to the software according to the internal gate cross-sectional area determined by the software and the product structure. For the analysis of gating, we have 4 plans, they are as follows: Plan 1 has a total of five gates, which are equally distributed. And the pouring is balanced, which can realize the overall pouring. The pressure is relatively uniformly transmitted to ensure density. Attention should be given to the filling area at the top. There is a chance of cold material accumulation and filling and bad exhaust. Plan 2 has a total of three gates, and the high-volume region of the commodity corresponds to the large gate to ensure the filling efficiency and pressure transmission. However, thick gates can easily cause partial temperature to be too high causing deformation and bad effects on the mold. Meanwhile this positioning will lengthen the filling stroke. Plan 3 and Plan 4 each have a total of three gates, and the high-volume region of the commodity corresponds to the large gate to ensure the filling efficiency and pressure transmission. However, thick gates are likely to induce excessive partial temperature, causing deformation and adverse effects on the mold.
The program completes the estimation of the four plans by setting up process conditions and performs multi-dimensional big data statistics. The program recommends Plan 1 as the best pouring plan to test the smooth aluminum liquid flow.
3.2 Determination of discharge system
After verifying the pouring plan and following the suggested plan 1, the product flow analysis is performed. The below figure shows the confluence of flow pattern and the location of the end of flow according to flow pattern direction. At the confluence and end of molten aluminum flow, a discharge system is added to efficiently discharge the cold material and ensure casting consistency.