Cloud-based simulation for low-pressure die-casting of copper alloys

The result of this Fortissimo experiment is the ability to simulate the flow of metal in a mould using open-source software in order to improve the design of moulds and also the design process. The success of the entire system depends on the quality of the castings (taps and valves) obtained. To avoid cracks and defects, it is therefore essential to design the moulds and the casting channels to obtain a laminar flow in the liquid metal and a constant cooling gradient throughout the final piece. Currently, the design of moulds and filling channels is entrusted to the experience of mould makers in collaboration with experts from the foundry. Generally, the exchange of experience has obtained good results, but it is often necessary to modify the mould several times and repeat tests before committing to production. The application of HPC-based simulation avoids the need to make expensive, physical redesigns of the mould. The cost of designing a mould using the traditional trial and error is approximately €41k. The use of Cloud-based HPC in this process produces a saving of around €8k because fewer iterations and less testing are involved. The cost of the computing cycles needed to perform these simulations is ~€2k. This results in an overall saving of €6k per mould. Over a year, IMR will design 8 sets of moulds representing an overall saving of €48k. Against this the need to train IMR staff to use the system and the software is a once-off cost of around €3k. The use of a Cloud-based-HPC system rather than the purchase and maintenance of an in-house system can represent a considerable saving. In particular when the utilisation of an in-house system falls below 50% of its peak capacity, then it is cheaper to use a Cloud. The use of open-source software represents a further saving.