High-Precision Shell Die Casting with ProCAST Optimization

At Ningbo SAIVS Machinery Co., Ltd, we take pride in being a trusted and experienced manufacturer of precision aluminum die cast components, offering customized solutions for the automotive, machinery, and industrial equipment sectors. In our pursuit of excellence, we have recently completed a die casting process optimization project for a high-demand shell component used in automotive assemblies — a case study that exemplifies our engineering capabilities and commitment to quality.

This shell body, a core part in an auto system, plays a vital role in housing internal components. The design includes thin walls (2.5 mm–5.5 mm), strict airtightness and strength requirements, and tight dimensional tolerances. Its complex geometry and need for mass production made it a challenging yet ideal candidate for pressure die casting.

Designing for Defect-Free Production

The project began with a thorough structural analysis of the casting, followed by the development of two gating system schemes. We used ProCAST simulation software to carry out digital modeling, which allowed us to:

• Visualize molten metal flow behavior

• Predict thermal gradients and solidification paths

• Locate potential shrinkage cavities, porosity, and cold shuts

Through comparison, it was clear that the tangential annular gating system outperformed the conventional design. This layout directed molten aluminum into the cavity via a ring-shaped runner surrounding the shell. The tangential entry ensured even distribution along the circumference, which prevented core impact, reduced air entrapment, and improved mold filling efficiency. Such balance is critical for thin-walled castings, where any uneven solidification can lead to defects or incomplete filling.

Optimized Mold & Runner System Design

To further reduce risk and optimize casting flow, we implemented:

• Arc-contracted runners with gradually reduced cross-sections to prevent back pressure and turbulence.

• Strategic overflow grooves and venting systems to evacuate gas and prevent porosity.

• Push rod placements that avoid visible marks on the part surface.

• Cooling water channels below high-mass areas to ensure uniform solidification and avoid hot spots.

• A sprue tailored for a 60 mm die casting machine chamber, with a 10 mm thickness and 10° draft angle to ensure smooth demolding.

Our simulation-driven approach revealed that the earlier designs caused isolated hot zones that lacked effective feeding paths, resulting in shrinkage holes. The optimized gating and cooling systems corrected these issues by transferring solidification fronts toward risers and overflow zones where defects could be more effectively controlled or eliminated.

Material Selection & Production Validation

The shell is cast from YL113 (Al-Si-Cu alloy), a widely used aluminum alloy known for:

• Excellent fluidity

• High wear resistance

• Good gas tightness

• Stable mechanical properties

After simulation and design refinement, the optimized die casting process was validated through production trials. The test results showed:

• Zero shrinkage porosity

• Smooth surfaces with no cold shuts

• Dimensional conformity to technical specs

• Increased yield and reduced scrap rates

Moreover, the final casting had a machining allowance of just 0.5 mm, reducing post-processing costs and lead time. With a parting surface optimized for ejection and minimal core tightening force, the entire process proved highly efficient for large-scale production.

Why Choose Ningbo SAIVS for Die Casting Projects?

At SAIVS, our core strengths include:

• In-house mold design and manufacturing

• Advanced simulation tools (ProCAST, CAD/CAM)

• Strict quality control systems (ISO standards)

• Experienced technical team for customized projects

• Competitive pricing for large-volume production

We serve clients worldwide with die cast parts used in automotive components, hydraulic housings, pump casings, gearboxes, and more. Our team is well-equipped to collaborate on complex parts that require tight tolerances, multi-cavity mold development, and full-process support.

If you're seeking a reliable aluminum die casting manufacturer in China, capable of delivering high-quality, defect-free, and cost-effective components, Ningbo SAIVS Machinery Co., Ltd is your ideal partner.

Contact Us Today to Start Your Project

Company: Ningbo SAIVS Machinery Co., Ltd
Address: NO. 626 Yuncai Road, Yunlong Town, Yinzhou District, Ningbo, Zhejiang, China
Tel: +86-574-88188161
Phone/WhatsApp: +86 13905748980
Email: seo1@saivs.com
Director/CEO: Mr. Jackie Zhou

We look forward to helping you with your next project and becoming your trusted Die Casting supplier from China.