Application FLOW-3D design and development of die-cast magnesium alloy instrument panel bracket
Schaufler Tooling is a well-known German manufacturer of die-casting molds for large aluminium and magnesium alloys. The products mainly involve: aluminum-magnesium intake manifold, aluminum-magnesium transmission, oil pan, structural parts and body parts, engine block, etc.
Below is a 2.5 mm wall thickness of a die-cast instrument panel bracket (Jaguar X150) made by Schaufler Tooling.
Casting shape
Discussion 1: The influence of punch movement in the press chamber on the coil gas
The effect of punch movement in the pressure chamber on the coiled air
Optimized punch movement
Discussion 2: Mold design
Filling analysis (temperature distribution) of the original mold design
Filling analysis (temperature distribution) of the original mold design
Problems with the original design
The runners are symmetrical, but the parts are asymmetrical
Since the volume on both sides of the product is not the same, the symmetrical runner design had to be modified, and the simulation continued after the sprue was changed.
Filling analysis (temperature distribution) for the first correction
The location where the gas is last discharged from the mold
Filling analysis of the first correction (oxide film distribution)
The result of the distribution of the oxide film
Based on the distribution of the oxide film, define the location of the overflow
By applying FLOW-3D software to perform punch movement, filling analysis (temperature, coil gas, oxide film), etc., the mold design and process design are improved, and finally the perfect thin-walled die-cast magnesium alloy instrument panel bracket is produced.
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