Computer aided foundry die-design

In the design of die casting dies, the object is to produce sound casting as cheaply and rapidly as possible. At the same time consideration must be given to suitable die size, locations of gating system, and selection of an appropriate die casting machine. Foundries in many cases encounter difficulties to ensure shortened lead-time in designing a new die for new product. A lot of estimations have to be done which use fundamentally based on previous experience and application of various mathematical and empirical equations. In this work, main die design procedures and related equations are presented in a logical way. A computer program is developed to estimate main die elements based on the geometry input of casting shape. After initial inputs have been given, the system does full calculations, optimizes selections, and lists main die element sizes. The program can present die characteristics and casting machine characteristics. From both characteristics the optimum die elements were optimized. Optimum filling time and gating dimensions among other elements of die are estimated. Cooling time, cooling channel locations, and flow rates relations are estimated and presented. (C) 2003 Elsevier Science Ltd. All rights reserved.