A numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting

The optimization of flow characteristics such as filling time, flow velocity, viscosity and temperature play a vital role in the die-casting to enhance the casting soundness. Experimental trial and error methods for optimizing the flow characteristics of mold filling are costlier and time-consuming methods. A digital approach could significantly minimize the cost and time for the prediction of the flow characteristics of the casting. Z-Cast Pro is the casting simulation software used for simulating the whole casting process such as filling, solidification etc. This software basically utilizes the finite difference and finite volume approximation techniques to numerically unravel the molten metal flow and solidification equations. In this study, A 3D model of the valve housing is used to analyze the mold-filling behavior through high and low-speed plunger movement of the molten Al 6061 alloy using Z-Cast Pro software version 24. Higher-speed plunger movement required a total mold filling time of 0.226548s while 0.285920s is the total mold filling time needed for the low-speed plunger movement. The flow behavior of the molten alloy reveals that the low-speed plunger movement with a total filling time of 0.285920s is predicted as the optimized flow characteristic to fill the mold cavity. Uniform temperature distribution in the low-speed plunger movement also eliminates casting flaws such as voids and porosities.