Computer Simulation of Solidification Process in the Gravity Die Casting

A basic three dimensional thermal model has been developed to simulate the solidification sequence for gravity die casting process. The finite difference method was used to analyze the solidification process during all the casting cycles. The prediction of die temperature in the quasi-steady state was analyzed by the boundary element method. The influence of die cooling on the heat flow in the cast/mold system was also investigated. Predictions of the computer simulation on temperature profiles and location of shrinkage defects were in good agreement with those observed in experimental die castings. Models of computer simulation which is developed by this work can be useful for the design and process control of die casting.