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Inytialgo

Case studies

Real die casting projects: the problem, what changed in the die and the process, and the result on the shop floor.

  1. Original and redesigned ejector plate, with peak displacement dropping from 0.92 mm to 0.13 mm

    Case study · Simcenter Simsolid

    Ejection stiffness in HPDC: from 8 to 3 tonnes of force to eject the same part

    A thin-walled part with 0.1 mm flatness: Simcenter Simsolid showed the ejector plate deflecting, and the redesign cut the ejection force from 8 to 3 tonnes.

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    8 → 3 t Force to eject the same part (−62.5%): proof it no longer distorts

  2. Filling simulation of a thin part, with the gate at the bottom and overflows spread around the outline

    Case study · Simcenter Inspire Cast

    LEAN HPDC: die casting with limited clamping force

    A 1,400 cm² part the industry sized for a 900-tonne machine runs on a 580-tonne one: plunger choice, uniform wall, filling in Inspire Cast and thermal overflows.

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    580 t Machine it runs on, where the industry called for 900 t

  3. Die casting die with solidified metal escaping at the parting line, next to the air evacuation block

    Approach · Vacuum-assisted die casting

    Making vacuum-assisted die casting stick to reduce filling defects

    Vacuum with passive chill blocks and one suction point: filling simulation places it, a tight die makes it work and the right device keeps it stable shot to shot.

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