High-Pressure Die Casting (HPDC) is a casting method used for producing a variety of product including those which entail complex forms or smooth surfaces. HPDC involves injecting molten metal at high speed and high pressure into a mold cavity. Metallic alloys like aluminum, magnesium, and zinc are mostly used in the HPDC process.
How ADSTEFAN Transforms High-Pressure Die Casting Process?
The cost and lead time of developing dies of high-pressure die casting parts are generally higher and longer than those of other casting process parts of the same size. Thus, the money and time devoted to designing, launching, producing, reworking, and redesigning defective casting parts would be also greater, if the defects are found after the start of serial production.
ADSTEFAN provides reliable analysis of the HPDC process, starting from injection of the molten metal to solidification, in order to predict defects of casting designs at the early development stage. Hence, ADSTEFAN helps HPDC foundries and tool shops avoid loss and firefighting projects, which are caused by suboptimal casting designs and production conditions.
Moving object and Cyclic steady heat balance method (CSM) are ADSTEFAN’s unique tools that help to smoothen the new product introduction via reliable simulation.
ADSTEFAN’s moving object function directly handles the movements of ladles, plungers and other rigid bodies and simulates how these movements impact fluid flow behaviours and molten metal temperature, which was otherwise difficult with conventional simulation algorithm. Using this function, casting industry leaders and practitioners can accurately simulate the fluid flow of molten metal poured and injected into the sleeves by examining the rotation of ladle along with the position and velocity of the plunger tip.
ADSTEFAN offers the CSM function for users who values speed and efficiency. The CSM function calculates a steady state of heat balance in dies without running dozens of simulation shots. The mean distribution temperature calculated on CSM can serve as the initial temperature for solidification analysis and make the solidification analysis more efficient and reliable.
ADSTEFAN Features For High-Pressure Die Casting
The accurate and efficient simulation tools of ADSTEFAN benefit the automotive industry and many other industries, where the growing trends of electrification and green transformation demand many new and complex High Pressure Die Casting parts. In order to address customers’ challenging and time-bound requirements for casting designs, it is essential to design and produce casting parts right the first time. In case defects are built in your designs and production conditions and escape design reviews and prototyping, the recurring defects would delay product launch and production plans, which could cause huge loss of profits and liquidated damages too.
ADSTEFAN’s simulation can predict defects inherent in casting designs and production conditions on your desktop, and help foundries and tool shops to avoid costly containment and corrective actions on the shop floor as well as dire delays and debacles of projects in the marketplace.
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