Optimization of die casting tools is becoming more important to meet the customer quality requirements and, at the same time, managing production costs. The more complex the casting part, the more demanding is the tool design and the more difficult it is to reach an optimal layout. An example of such casting is this aluminum table base casting made by a die caster in the USA. The customer requirements are high and difficult to meet. The structural integrity throughout the casting is of utmost importance in order to assure the functionality of the end product, as it needs to support heavy tabletops, some of which are marble. The casting is also later subjected to elevated temperatures in a high gloss coating application. Any porosity close to the surface could create blisters during the heating cycle while the casting remains at an elevated temperature level. Therefore, the engineers have to prevent the formation of porosity near the surface of the casting. This paper explains how engineers have utilized the latest simulation technology to achieve and exceed the customer requirements.
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