Numerical Analysis of the Influence of Demolding Temperature on Final Distortion in Gravity Die Casting Process

Abstract Distortion can be a prominent issue in the production of metal casting components, especially when using metal dies. Existing research underscores the pivotal role of the temperature at which the solidified component is extracted from the mold in contribution to the ultimate distortion of the component. This numerical investigation seeks a comprehensive understanding of the factors governing deformation by employing simulations that emulate experimental conditions. The study utilizes coupled thermomechanical simulations, executed through the commercial software “Abaqus,” across varying demolding temperatures. The temporal evolution of distortion is examined, with a focus on influential factors such as elastic and thermal strain. A quantitative and qualitative comparison is drawn between simulation outcomes and experimental results. The difference between experimental and simulation results was observed to increase linearly with higher demolding temperatures. The potential for leveraging the qualitative similarity between experimental and simulation results as a foundation for the development of distortion control strategies is deliberated.