Die Casting News

Process Simulation and Optimizing Die Casting Lubricant Spray Patterns

Posted by Hill and Griffith Company on Nov 8, 2017 12:09:05 PM

Learn the Benefits and Limitations of Die Casting Process Modeling and Simulation, including die casting lubricant spray patterns

This series of three NADCA webinars is a brief overview of issues related to modeling and simulation of the die casting process. Emphasis is placed on making a distinction between modeling and simulation and understanding where simplifications necessary to successfully implement simulation software require special attention by the end user.


Part 1 - Background -

The first of three sessions addressing die casting modeling and simulation issues covers basic background material. The relationships between simulation and modeling is introduced with emphasis on the fact that simulation always requires modeling, but modeling does not necessarily require simulation. The concept of simulation is introduced as the numerical solution of models developed from basic models developed primarily from fundamental conservation laws. Modeling issues discussed include definition of problem boundaries, approximation of geometry, restriction of the phenomena (e.g. thermal, flow, stress, etc.) of interest, and the importance of boundary conditions. The special problems presented by widely varying spatial and temporal analysis scales are also introduced.
Date: November 14, 2017

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Part 2 - Selected Technical Details -

The basic equations of physics do not change from one simulation package to another, but the solution procedures may vary. Some of the key differences of finite element, finite volume, and finite difference are briefly illustrated and the pros and cons of each are reviewed. Specialized elements available in many general-purpose CAE packages, but generally not available in casting packages, are also illustrated to help understand why questions need to be asked to fully understand how a casting simulation package is generating certain types of results. Geometry and meshing issues and the impact on the solution are considered. Some of the problems inherent in comparing simulation results with casting results are illustrated including the fact that nearly all such comparisons are qualitative. The session concludes with an overview of typical solution rendering techniques and their pros and cons. 
Date: November 15, 2017


Part 3 - Limitations -

This session is a review of the range of modeling simplifications that are used to make simulation tractable, but then require careful interpretation of the results. Included are time-scale issues and transient versus steady state results including temperature creep; modeling of spray; selection of heat transfer coefficients; technical issues modeling heat loss during fill; cooling line performance, and venting performance. The benefits of special purpose models to provide engineering insight to supplement simulation results in select cases is also illustrated. 
Date: November 16, 2017

Purchase a single webinar
Part 1: Die Casting Process Modeling and Simulation – Background
Part 2: Die Casting Process Modeling and Simulation - Selected Technical Details
Part 3: Die Casting Process Modeling and Simulation – Limitations

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Purchase access to the entire webinar series
Die Casting Process Modeling and Simulation Webinar Series

These webinars will take place at 1pm CDT on the dates listed. The cost per webinar is $69 for Corporate Members, $99 for Individual Members or $119 for Non-Corporate Members. Please note that registering for a webinar grants you access to the live broadcast on the given date. No recordings or pdfs of the presentation will be issued.

Headquartered in Arlington Heights, IL, the North American Die Casting Association (NADCA) represents the voice of the die casting industry, representing more than 3,100 individual and some 300 corporate members in the United States, Canada and Mexico. NADCA is committed to promoting industry awareness, domestic growth in the global marketplace and member exposure.


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We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

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We are pleased to provide samples in quantities large enough to allow you to "try before you buy." Die Casting and Squeeze Lubricants- Diluco®, Permanent Mold Coatings- Concote™, Plunger Lube™- Graphite and non-graphite oils and pastes with excellent anti-wear properties, Casting Operations Products: Start-up lubes, Ladle coatings, Anti-soldering pastes, Water glycol, Trim press lubricants, Surface protection for casting storage, Corrosion protection for die storage, Cleaners for machines and dies, Corrosion protection for machines, Heat treatment quenchants, and Heat-transfer fluids. Also, Industrial Lubricants Griflube®, Hydraulic fluids with fire-resistant and anti-wear properties, Bio-Syn natural ester-based hydraulic fluid, Way oil knuckle lubes and Metalworking Fluids- Grifcut™

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting lubricant, Die Casting Technical Support, Aluminum Die Casting

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