Abstract: With the increasing power of computer hardware and software, computational simulation and visualization are becoming increasingly important tools to understand and improve industrial processes, such as metal casting. Computer-aided visualization is increasing the power of all of the tools available to the solidification process engineer, including previous literature, mathematical modeling, laboratory experimentation, and online measurement of the casting processes. Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. In this thesis, main emphasis will be on the optimization of process parameters in High pressure die casting. A case study of compressor housing is considered where the flow simulations results are analyzed for optimization. An analytical approach is discussed by using software Ansys Fluent to analyze the behavior of molten metal at different stages of time by observing the results of temperature variations, pressure variations and liquid fractions by applying the input parameters molten metal temperature, die temperature and velocity of flow. The model of the component with spreader design, runner design, gate location and overflows is done in 3D modeling software Pro/Engineer.
Keywords: Die casting, metal casting process, spreader design, runner design, gate location.