Design of die casting process of top cover of automobile generator through numerical simulations and its experimental validation

In this study, die casting of the top cover of an automobile generator made of aluminium alloy is designed with the assistance of the numerical simulation tool ADSTEFAN. Die casting with an original design of the single runner system was investigated, and casting defects were found on the surface. Fluid flow and solidification heat transfer were simulated for this particular die casting design. Casting defects similar to those found in the investigation were predicted using filling time, temperature distribution and residual gas flow pattern obtained from numerical calculations. Results show that the numerical simulation system is accurate and reliable. With detailed information of the casting process obtained from the simulation, an improved die casting design that uses a double runner system is recommended. Numerical simulation was conducted on the improved design, and no casting defects were found. The improved casting design was implemented, and sound casting was obtained.