Conversion of a Vacuum-Assist Casting to a Conventionally Vented Casting with Casting Simulation

In the current competitive environment, the capability to produce high quality die casting components whilst reducing production cost and development times is a challenge the foundry industry must face up to. Whether it is the design of a new component or redesign of existing products, computer aided modeling has proved that there are several cost savings to be gained in the process development and production stage. By eliminating product defects and reducing scrap and rework, foundrymen can achieve improved and more consistent product quality and more efficient designs that produce higher yields.

Thanks to advanced computer aided technologies, process modeling provides valuable information that facilitates participation by the foundry engineer early in the product development stage. This reduces the time between the concept stage and production stage in the life of a new component. Using this technology Honda Engineering of North America converted an existing vacuum-assist die casting to a conventionally vented casting. There are several design challenges associated with using a vacuum vented design. Also, the time and cost saving benefits associated with moving to a conventional venting system motivated Honda Engineering of North America to convert several of the company’s vacuum assisted die designs to conventional vented designs.

In this article we will describe the lessons learned in making the switch from a vacuum to conventional venting die design, how simulation was used to correct potential defects in the casting due to the air management change, and helpful guidelines for successful implementation of conventional venting.