Casting simulation processes have become an integral part of the fast-paced development process. In this case, the focus of development is on the optimization of components and the improvement of process flows. Modern simulation technology can provide a structure that is both reliable and traceable. The first simulation process should usually be started at the inquiry stage. Although the company has not yet received any orders, the company should conduct further research on the components being inquired. The preparation of the quotation should be as close to reality and actual conditions as possible to avoid unexpected situations when production starts, thereby avoiding unnecessary cost increases. Therefore, when preparing the quotation, although it is not certain with which company the customer will eventually place an order, and the requirements for the company are high, the time is short and there is no upfront payment at all, a realistic feasibility conclusion is drawn.

Simulation During the Development Phase

The simulation must be as inexpensive as possible, and the results should be delivered as quickly as possible and should reflect the actual situation as accurately as possible. Despite the time pressure, the results on mold filling, flow pattern, flow rate, air inclusions, porosity, mold temperature, etc. should be as accurate and convincing as possible. The simulation should support and improve the conclusions about the mold or production costs so that the quotation can be prepared as accurately as possible.

Here, we take a shock tower die-cast structure made of the aluminum alloy AlSi10MgMn as an example. It weighs 5.9 kg and has a wall thickness of 2.5 mm. The component is made using a vacuum die-casting process and is CNC machined in the area of the mounting holes. In addition, it is heat treated to increase its strength and ductility. The component measures approximately 530×520×440 mm.

In the automotive body sector, aluminum die-cast structural parts have always been in competition with high-strength thin steel sheets. Compared with steel materials, aluminum structural parts have advantages such as high functional integration, outstanding dimensional accuracy and special energy absorption capacity, which makes aluminum components still very attractive in terms of cost and growth rate.

According to the requirements mentioned above, an intuitive and easy-to-use interface and quick input of specified parameters are crucial for the simulation system. For simple and fast processing, the "usability" of the system is an essential factor, because users may not work with the simulation system every day. For this reason, relevant features are designed in the Inspire Cast 2019 system to keep costs as low as possible.