Numerical Simulation and Optimization of Aluminum Die Casting for Enhanced Part Quality

This paper investigates the injection process of aluminium alloys through a virtual simulation approach, aiming to optimize technological parameters for improved product quality. The study focuses on the behavior of the molten material during cavity filling, highlighting aspects such as flow uniformity, temperature distribution, and areas prone to defects like porosity and shrinkage. A threedimensional model of the mould and the part was analysed to assess the influence of the injection gate’s positioning and geometry. The simulation results revealed critical regions associated with turbulent flow and uneven solidification. Several design iterations were carried out to reduce structural imperfections and achieve balanced mould filling. The outcomes of the study offer a set of recommendations for improving the performance and reliability of aluminium injection processes, supporting efficient and defect-free production in industrial applications.