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Die Designing and Molten Metal Flow Analysis for Intermediate Flange

K Maheswari and G Sureshkumar
Faculty of Engineering, University Malaysia Sarawak (UNIMAS), Kota Samarahan 94300, Sarawak, Malaysia

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.