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Companies dealing with die casting need to design, develop and produce high-performance products. Simulations play a crucial role because they help designers to check every point of the product, resolving critical issues during the production phase.

What are the advantages of good design in companies that operate die casting?

• Reduction of time-to-market: simulations allow rapid interventions in different areas like temperature, filling speed, filling pressure, etc.
• Cut production costs: simulations guarantee accurate results

Altair Inspire, the best manufacturing software

In the manufacturing sector, Altair developed a powerful and accurate software, making design accessible throughout the product development life cycle, from concept to production.

Some of the potential of Altair Inspire:

• Create and edit projects with ease
• Optimize the process while respecting production constraints
• Simulate filling speed
• Analyze cooling systems
There are different modules: Mold module – is suitable for the injection molding of plastic materials, Cast– specifically designed for metallic materials, Extrude – for the extrusion of metals, Form – designed to simulate cuts and bends. Inspire has become an indispensable tool for all designers and product engineers.

Case study created with Inspire: Die Casting Filling Simulation

Working with our client, we analyzed the potential of the Inspire software with a comparative analysis: experimental data and simulation data. We initially imported the provided geometry for topological preparation for the die casting simulation.
The first step consists of:
• Divide and group the various characteristic components of the die casting into subgroups (casting, feeding system and wells)
• Cut out some features that make the simulation run slower
The next step consists in setting up the simulation by setting, according to the technical specifications:
• Unit of measure
• Set the gravity direction and jet properties
• Set feed system, wells and mold properties
• Set of injection chamber and piston stroke
Once the simulation parameters have been set, the simulation will be done in quickly and accurately.

The outputs generated will regard different areas such as:
• Temperature
• Filling pressure
• Filling speed
• Trapped air remaining at the end of filling
• Cold joints

The simulation results will also allow the evaluation of the parameters listed above throughout the process from filling, to its solidification up to cooling. The simulation will therefore permit to modify the parameters to obtain the desired results. This process helps to reduce errors in the production phase, which is reflected in a shorter time to market compared to traditional processes.

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