Design optimization of gate system on high pressure die casting of AlSi13Fe alloy by means of finite element simulations

The diecasting modern industries are moving towards the proof-of-concept methods based on finite element simulation (FEM), abandoning the traditional trial-and-error. Aluminum DC is a very complex process because the mold filling problems. In the new design production system approach, the FEM simulations play an important role, virtually recreating the entire casting phases. In this research, simulations were carried out using a commercial software to optimize the gates and runner's design of a thin panel component in G-AlSi13Fe aluminum alloy actually realized in AA3004 sheet metal formed. Filling analysis was used to define the gate's size, its correct positioning and the runner system design.