Computer simulation has become a valuable tool for die design over the past decade as the available software has become more capable and usable.
Computer simulation is the application of computational methods to solve the equations that describe fluid, thermal stress and displacement relationships that apply in any mechanical system. The die cast specific simulation tools (e.g. ProCast, Magma, SimTech, EKK, Flow 3D, etc) may handle model work automatically and can save considerable time and effort in modeling and simulation tasks.As applied to design, the applications of simulation are thermal and heat transfer problems, fluid flow problems and stress and displacement issues. The basic objective is to optimize the die before steel is cut. The benefits most often cited are savings down-stream in the development cycle due to less process development time and tooling rework and cost-savings throughout product life-cycle.