Calculated initial temperature distribution in die and shot sleeve via die cycle warm-up. (All images courtesy CD-adapco.)
However, HPDC can be difficult to control, with defects such as gas inclusions and misruns being common problems. Additionally, it is challenging to simulate due to the complexity of its physical processes, such as multiphase flows consisting of both melt and gas. Yet, given the high cost of HPDC tooling, trial-and-error is not an acceptable alternative.
To address this issue, STAR-Cast v11.02 features a new High Pressure Die Casting module, providing casting engineers with an accurate and user-friendly tool for designing stronger, lighter and higher-quality cast parts.
STAR-Cast integrates computational continuum mechanics with a detailed casting model. Input parameters entered through the program’s graphical user interface (GUI) include:
- The cooling and heating system conditions of the mold insert
- Die cycle warm-up
- Shot curve
- Air outlet conditions
- Casting temperature
The new module resolves all the physics using a completely coupled approach to simulate mold filling, air entrapment, misrun formation and die venting. It provides casting engineers with a clearer picture of the HPDC process, letting them spend more time optimizing their processes and designs and less time fighting with defects.
STAR-Cast is built as a plug-in to CD-adapco’s STAR-CCM+ thermal-fluid simulation platform. Much of its HPDC logic came out of a partnership with Access e.V. and its experience with casting and metallurgy.
In addition to the new high-pressure die casting module, STAR-Cast v11.02 has been fine-tuned to streamline its overall simulation workflow. Turnaround time of cast simulations has been improved with the addition of a new compressibility feature and smarter determination of iterations per time step. A new material database builder has been added to support integration of proprietary materials into the user’s material database.
“High-Pressure Die Casting is quickly becoming the manufacturing process of choice for the mass production of parts in the automotive industry,” said Jean-Claude Ercolanelli, CD-adapco senior vice president of product management. “More and more, companies are turning to simulation to optimize these complex processes, with the goal of obtaining repeatable product quality and reducing manufacturing costs.”
By focusing on ease-of-use, without sacrificing accuracy, STAR-Cast v11.02 helps to lower the barriers to HPDC adoption.
What HPDC casting issues would you like to assess with STAR-Cast? Have you tried the plug-in? Let us know in the comments below.