Similar to aluminum die-casting, computer programs can be used to simulate the flow of the liquid copper into the rotor casting die, as well as to optimize gate and runner design. In the ICA/CDA copper die-casting project, the Flow 3-D simulation package was used by Walkington Engineering to optimize die filling behavior. As shown in Figure 11.7.1, simulation can reveal the presence of bubbles forming in the end rings when inappropriate die filling conditions are used. Simulation is an inexpensive method of fixing processing problems, allowing solutions to be readily transferred to die-casting cell.
Figure 11.7 1 Simulation of the liquid copper flowing from the runner, through the gate and into the rotor end ring