Design optimization of clutch housing mold by fluid flow and solidification simulation

Aluminum die casting is so complex where flow momentum is critical matter in the mould filling process due the high velocity of the liquid metal. Actually, in complex parts the exact calculation of mould filling performance with using experimental knowledge is almost impossible. Aluminum die castings play a definitive role in the manufacturing of lightweight automobile bodies. Hence it is more essential today that these castings be produced with the high quality methods. In this condition the simulation is becoming more important in the designing procedure. This saves time and reduces the cost of the casting system design, which is an advantage of using simulation programs. Also, economical utilization of materials can be obtained when the quantity of test castings is decreased. This paper describes the advantages of the clutch housing die casting mold simulations to achieve better casting system design in High pressure die castings (HPDC). Filling analysis is used to determine the size and location of the gate as well as proper runner system design for ensuring a complete and balanced filling of the clutch housing part.