Application of Reverse Engineering and Numerical Simulation in the Development of a High-Pressure Die Casting Process

The paper presents the application of 3D optical scanning and numerical simulation in the development of a high-pressure die casting process for a differential transmission cover. The geometry of the existing casting was digitized using a 3D optical scanner, followed by reconstruction of the CAD model using reverse engineering. Based on the reconstructed geometry, the gating system and overflow elements were defined, and a numerical model of the die casting process was developed. Numerical analysis was performed using the ProCAST software package, with the filling of the die cavity, solidification of the molten metal, temperature distribution, and the potential occurrence of characteristic casting defects, including air entrainment and shrinkage porosity, being analyzed. The simulation results showed favorable filling and solidification behavior, with only localized areas exhibiting an increased potential for shrinkage porosity. The conducted research demonstrates the applicability of combining 3D scanning, reverse engineering, and numerical simulation as an effective approach to the development and optimization of die casting processes.