High pressure die casting (HPDC) simulations are typically quite complex. To accurately model the entire physical process, heat transfer, melting and solidification, air entrainment, surface defect tracking and cavitation all need to be accounted for. In this three-part webinar series, we will simulate the entire HPDC process in FLOW-3D Cast. We will also demonstrate the power of the new process-oriented workspace that implements the necessary physical models and numerical defaults while setting up the stages of thermal die cycling, filling, solidification and cooling.

Following the first part of our series on thermal die cycling, we will be holding the second part of our series on filling on November 15 at 1:00 pm EST. All registrants will receive a copy of the recording.

In part 2 of our series, we will analyze the filling of the die based on the steady state thermal die profile from the thermal die cycling simulation from the first webinar. We will demonstrate how to implement a properly-designed shot sleeve profile to rapidly push metal into the die. In this stage of the simulation, the molten metal needs to quickly fill the die to prevent early solidification. At the same time, care should be taken so that the liquid metal front does not fold over itself causing air entrainment that results in internal defects or any potential surface defects formed by oxides. This is one of the more challenging simulations as it entails accurately tracking the metal front at high pressures and velocities.