Numerical determination of process parameters for fabrication of automotive component

The casting defects that are caused by molten metal are cold shut formation, entrapment of air, gas, and inclusion. But the control of casting defects has been based on the experience of the foundry engineers. One of the most parameters that can influence the casting defects is cooling rate. In this paper, computer simulations have been carried out to analyze the flow of molten metal and effect of die temperature on the cooling rate and subsequently the casting defects. Flow patterns of molten metal in one of the Iranian automotive component were examined to find the optimal temperature for the die-casting die temperature. The finite element ProCast software was used for simulation and results of simulation was compared with the experiment. The calculated results for automobile Ladder frame body to control the die-casting process have achieved good agreements with the experimental data. Results show that temperatures between 20°C to 25°C are good for the die casting.lic par