In the modern manufacturing industry, die-casting process as an important metal forming technology, its production efficiency and product quality directly determine the cost of products and market competitiveness. With the advent of Industry 4.0, the application of simulation technology in the field of die casting production has begun to play an increasingly important role. Through production process simulation, we can predict possible problems without interrupting the production line, and make necessary adjustments and optimizations before physical production. We will explore how simulation techniques can be used to predict and improve problems in die casting production.

1. Challenges in the die casting production process

The die casting process involves high temperature, high pressure and rapid cooling, which together act on the metal material and have a significant impact on the shape, size and internal quality of the casting. Common problems include short bursts, porosity, shrinkage, deformation and cracks. The existence of these problems not only reduces the product qualification rate, but also may lead to mold damage and production stagnation.

2. Application of simulation technology in die casting production

1）. Temperature field and flow analysis: By simulating the flow and cooling behavior of molten metal in the mold, it is possible to predict and optimize gate design, pouring speed and cooling channel layout.
2）. Solidification process simulation: Analyze the phase transition process of metal from liquid to solid, predict the generation of shrinkage holes and porosity, so as to adjust the process parameters and mold design.
3）. Stress and deformation analysis: simulate the thermal stress and mechanical stress of castings during solidification and cooling to prevent deformation and cracking of castings.
4）. Mold life assessment: By simulating mold temperature and stress distribution under cyclic load, predict possible wear and fatigue areas, guide mold maintenance and replacement plan.

3. Implementation steps and case analysis

1）. Create simulation models
Firstly, it is necessary to establish an accurate mathematical model according to the die casting design and die structure, and define the corresponding boundary conditions and material properties.

2）. Simulation experiment
Simulation experiments are run on the computer to observe the filling, solidification and cooling processes under different process parameters, as well as the response of the castings under stress.

3）. Result analysis
By analyzing the simulation results, the potential defect locations and causes are determined, and suggestions for optimization are put forward.

4）. Verification and adjustment
Verify the accuracy of simulation prediction in actual production, and adjust the simulation model according to the actual situation of the product.

5）. Continuous improvement
The application of simulation technology is a process of continuous improvement, which requires continuous collection of production data and updating of simulation models to adapt to the continuous changes in production.

Conclusion:

Simulation technology is a powerful tool for die casting production, helping engineers and manufacturers anticipate possible problems early in production and allowing them to test and optimize without compromising production schedules. By integrating simulation technology into daily production, enterprises can not only significantly improve the primary pass rate of products, but also extend the life of molds, reduce production costs, and ultimately improve the overall market competitiveness. Aiming at the application of simulation technology in the production of die casting machine and its benefits, this paper can be used as a reference to optimize the production process. Meanwhile, the arrangement of its content and structure will help it get good exposure and ranking on the Internet search engine.以上翻译结果来自有道神经网络翻译（YNMT）· 通用场景