Prediction of Possible Errors in the Product Before Metal Injection Molding Production

Metal injection is a method in which non-ferrous metals such as aluminum are melted and injected into a mold with high speed and pressure. This method allows the production of thin-walled and complex-shaped parts with high precision and in mass production. Metal injection successfully meets the needs of many industrial areas such as automotive, defense, agriculture, gift ornaments, and white goods production. Although the products produced with this method have superior advantages with respect to the production speed, precision and surface quality, they also have disadvantages such as the possibility of having surface oxides, air compression, and macro and micro pore formation that may occur during casting. Detecting the defects that may occur before mold making against the formation of these errors is of great importance in terms of production cost and product quality. In this study, a piston connecting rod mold to be produced from aluminum material was designed, casting flow analysis was performed with the finite element method, and risks such as filling parameters of the molten metal into the mold, cold junction, turbulence, and air compression were determined, and possible errors were predicted before starting the mold production, and the mold design was optimized in line with the analysis results, and production efficiency was improved.