Abstract—The die casting process is an effective near net shape manufacturing process for producing geometrically complex components which require a high production rate and an excellent surface finish. However, one problem area has been indicated that die castings are often rejected by die casters as a result of being machined, and the defects for causing the rejections are frequently not clearly defined. And also the common defects found in these defective castings were categorized as follows: porosity, cold laps, flow lines, aluminum oxide inclusions, lubricant or mold coating inclusions, and mechanical cracks. To develop 3-D of intermediate flange as per the customer requirement using 2-D drawing in Pro/E. To Develop Die for intermediate flange {core, cavity, runner and gate, etc.}, using Pro/E software. Make molten metal flow analysis for this Die using Magma software.

Index Terms—Die design, Metal flow analysis, Hot chamber die pressure casting

Cite: K Maheswari and G Sureshkumar, " Die Designing and Molten Metal Flow Analysis for Intermediate Flange," International Journal of Mechanical Engineering and Robotics Research, Vol. 2, No. 4, pp. 176-182, October 2013.