The die cast industry has long used trial and error as a development method, resulting in growth of the use of CFD (computational fluid dynamics) software. This book will discuss the governing laws of the fluid dynamics that have an effect on die cast die and die cast process design. ATLAB and Visual Basic code are listed in for every stage of product, die and die cast process design. Readers will learn about: the advantages and limitations of the die cast process; the implications product design has on the quality of the die cast part; how die cast die and process design can affect the physical properties of the casting; the calculations die cast die and process designers have to do; choosing the die cast machine size and the proper gate size; and how to properly design gas ventilation systems, identify an ideal fill time, and calculate fast and slow shot velocity. This book will interest product designers that design die cast parts and die cast die and process engineers and designers. TOC:Introduction.- Introduction to fluid dynamics.- Part design.- Die design.- Process design.- Quality.- Computer simulations. This book is the result of 40 years of the combined authors¿ experience in mechanical and fluid dynamics engineering. It gives an overview of product and process development from the analytical standpoint. This book has not been intended to revolutionize the casting industry. The principals of fluid dynamics and static mechanics were largely developed in the nineteenth century, but process development still largely remains a trial and error method. This book is intended to underline the principals of strength of materials and fluid dynamics that are the foundation of the casting product and process development. This book has been written as a resource and design tool for product and process engineers and designers who work with aluminium castings. It combines many aspects of product and process development, which include the basic principals of static mechanics and fluid dynamics as well as completely developed applications allowing solving problems at every stage of the development process. This book has five main parts: (1) overview of casting processes, (2) fluid dynamics, (3) strength of materials, (4) sand casting, permanent mould, and die casting process development, and (5) quality control. Casting of Light Metals 1(12) Casting Processes 1(1) Sand Casting 1(2) Gating System 2(1) Risers and Chills 2(1) Permanent Mould 3(2) Gravity Casting 4(1) Low-pressure Permanent Mould Casting 4(1) Counterpressure Casting 4(1) Die Casting 5(8) Die-cast Process 5(3) Die-cast Dies 8(1) Runner System 8(3) Cavity of Die-cast Die 11(1) Air Ventilation System 11(1) Ventilation Blocks 12(1) Introduction to Fluid Dynamics 13(30) Basic Concepts 13(5) Pressure 13(1) Viscosity 14(2) Temperature and Enthalpy 16(2) Equations of Motion 18(1) Boundary Conditions 19(4) Velocity Boundary Conditions at Walls 20(1) Thermal Boundary Conditions at Walls 20(1) Free Surface Boundary Conditions 21(2) Useful Dimensionless Numbers 23(3) Definitions 23(1) The Reynolds number 24(1) The Weber Number 24(1) The Bond Number 25(1) The Froude Number 25(1) The Bernoulli Equation 26(1) Compressible Flow 26(9) Equation of State 27(1) Equations of Motion 28(1) Specific Heats 29(2) Adiabatic Processes 31(1) Speed of Sound 31(2) Mach Number 33(1) The Bernoulli Equation for Gases 33(2) Computational Fluid Dynamics 35(8) Computational Mesh 35(1) Numerical approximations 36(2) Representation of Geometry 38(1) Free Surface Tracking 39(2) Summary 41(2) Part Design 43(54) Design of Light Metal Castings 43(1) Static Analysis 43(3) Moment of an Area 44(1) Moment of Inertia of an Area 44(2) Loading 46(1) Stress Components 47(8) Linear Stress 48(2) Plane Stress 50(1) Mohr's Circle 51(4) Hooke's Law 55(1) Saint-Venant's Principle 56(1) Criteria of Failure 57(1) Ductile Material Failure Theory 58(1) Brittle Material Failure Theory 58(1) Beam Analysis 58(13) Free Body Diagram 67(1) Reactions 67(1) Buckling 68(3) Bending Stresses 71(5) Normal Stresses in Bending 72(2) Shear Stress 74(2) Stresses in Cylinders 76(6) Press-fit Analysis 82(4) Thermal Stresses 86(1) Torque 87(6) Stress Concentration 93(1) Fatigue 94(2) MATLAB® Functions Used in Chapter 3 96(1) Process Design 97(60) Evaluation of Dimensionless Numbers 97(3) Gravity Pour 98(1) High-pressure Die Casting: Slow Shot 98(1) High-pressure Die Casting: Fast Shot 99(1) Flow in Viscous Boundary Layer 100(2) The Bernoulli Equation 102(6) Stagnation, Dynamic and Total Pressure 102(1) Gravity Controlled Flow 103(1) Flow in the Runner System 104(2) Filling Rate 106(2) Flow in a Shot Cylinder 108(8) Gas Ventilation System 116(9) Ventilation Blocks 125(1) Little's Formula 126(1) Poisson Process and the Exponential Distribution 127(5) Cooling 132(9) Lumped-temperature Model 132(6) Heat Flow into a Semi-infinite Medium 138(3) CFD Simulations 141(16) High-pressure Die Casting 142(10) Gravity Sand Casting 152(5) Quality Control 157(8) Basic Concepts of Quality Control 157(1) Definition of Quality 158(1) Definition of Control 158(1) Statistical Process Control 159(1) Tabular Summarization of Data 160(1) Numerical Data Summarization 160(5) Normal Probability Distribution 161(1) Poisson Probability Distribution 162(3) Appendix 165(8) Unit Conversions 165(6) Prefixes 171(2) References 173(2) Index 175