Numerical simulation of AZ91D alloy automobile plug in pressure die casting process

The many kinds of casting defects such as insufficient pouring, cooling separation, crack, shrinkage and so on were formed in the mold filling and solidification processes, which contributed to the final casting performance. Based on the mathematical models of mold filling and solidification processes, the numerical simulation of AZ91D magnesium alloy automobile plug in pressure die casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkage and slack were predicted. According to the simulated results, an improved scheme is proposed, and its workpiece defects are reduced largely. The predicted results are in good agreement with practical ones.