Finite element analysis for die casting parameters in high-pressure die casting process

The gating system and the overflow system were designed according to the casting structure during high pressure die casting (HPDC) process. The simulation was carried out by ProCAST software to visualize the injection chamber pre-crystallization and the flow of molten metal. The main work is to research four die casting process parameters, i.e. injection temperature, low-pressure velocity, high- and low-pressure velocity’s switching position, and high-pressure velocity. Experimental results show that the higher injection temperature and low-pressure velocity can mitigate the pre-crystallization of the injection chamber. However, when the low-pressure velocity exceeds 0.2 m·s−1, the air entrapment in the chamber occurs. Besides, when the high-pressure velocity is greater than 2.5 m·s−1, the overflow channel at the final filling position is covered by the liquid metal too early. Finally, the injection temperature of 650 °C, the low-pressure velocity of 0.2 m·s−1, the high- and low-pressure velocity’s switching position of 320 mm and the high-pressure velocity of 2 m·s−1 are obtained as the optimal parameters by the software simulation, which has been verified by actual production.