Numerical Simulation of Door Lock Plates Castings Produced by High Pressure Die Casting process

The integration of computer process simulations replaces traditional casting techniques that rely on trial and error to develop proof-of-concept before tooling is ever constructed. This paper evaluated the high pressure die casting (HPDC) for door lock plates using a commercial modeling code, FLOW-3D CAST, simulating the process and correlating it with practical experience. Filling analysis was carried out to predict defects, specifically, internal porosities, caused by air entrapments, and those findings were linked to an actual product produced inside a foundry for model validation. Simulation results show internal porosities caused by the gas entrapment/shrinkage at the exact locations observed on the real door lock plate cast.