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

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Abstract

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.

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Acknowledgments

The authors of the work want to thank (El Refay for Engineering Services, Egypt), the certified partner of Flow Science Inc. (developer of FLOW-3D CAST program), for providing the program's license to do the numerical work in this paper.

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Authors and Affiliations

  1. Mechanical Design and Production Department, Faculty of Engineering, Cairo University, Giza, 12613, Egypt

    M. G. Mahmoud

  2. Chemical Engineering Department, Faculty of Engineering, Cairo University, Giza, 12613, Egypt

    Amr Abdelghany

  3. Mechanical Engineering Department, Faculty of Engineering, The British University in Egypt, Cairo, Egypt

    Serag Salem

Authors
  1. M. G. Mahmoud
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  2. Amr Abdelghany
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  3. Serag Salem
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Correspondence to Serag Salem.

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Mahmoud, M.G., Abdelghany, A. & Salem, S. Numerical Simulation of Door Lock Plates Castings Produced by High Pressure Die Casting process. Inter Metalcast 17, 847–859 (2023). https://doi.org/10.1007/s40962-022-00797-7

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  • DOI: https://doi.org/10.1007/s40962-022-00797-7

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