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Die casting in mass production has the advantage of producing  complex shapes precisely, but the disadvantage of air entrapment in  high-speed injection molding. Plunger velocity control very effectively  avoids air entrapment. Using computational fluid dynamics (CFD), we analyzed  fluid behavior, the amount of air trapped, and air shutting caused by die  casting plunger movement. We calculated optimum die casting plunger velocity  control input to reduce or prevent air entrapment and air shutting in die  casting products. We also conducted optimization using a genetic algorithm  incorporating a CFD simulator.

Optimum Velocity Control of Die Casting Plunger Accounting for Air Entrapment and Shutting