Aluminum molds in casting

Energy savings in mass-produced castings that use metal molds rather than sand molds are comparatively high because metal molds can be used for more parts. The number of degrees of freedom in permanent molds is much lower than in sand casting, but it is still possible to cut costs using simulation.

In one case, the original gating system for a motorcycle fork produced using the tilt-pour casting process resulted in several quality issues. Worse yet, casting yield was only 49%. Simulation helped engineers eliminate filling turbulence, and a hotspot and its related defect. They used smaller gates, which boosted the casting yield by 18.5%. In addition, the faster filling of thin walls shortened solidification time to cut cycle times by 10%.