Computer Simulation of High Pressure Die Casting of Magnesium Engine Cradle

The use of magnesium cast components has become very important in reducing the automobile vehicle weight, thereby reducing fuel consumption. In the past, such parts have been limited to structural applications. The USAMP/USCAR Structural Casting Magnesium Development (SCMD) project team has successfully demonstrated that an application of a structural magnesium casting to an engine cradle is quite feasible. Computer simulation of casting processes becomes an essential tool for this development, since cradle applications are unprecedented. Numerous simulations were conducted to visualize the effect of geometry changes, process parameter changes, vacuum, and shot parameter changes. These results were used to identify the best possible configuration.