The failure of dies and its repairing options are very important in die casting industries. Of all the casting
processes available, pressure die casting finds wide applications in large scale production of complex
shaped objects with intricate geometries that require good surface finish and dimensional stability.
The cooling system employed in the die not only facilitates proper solidification of the cast components
but also helps in maintaining the die temperature and controlling the stresses generated during the cyclic
operation. The research work focuses on designing a die of H13 material for ADC12 cast part that is to be
operated on 160 Tonne Cold Chamber HPDC machine. The effect of cooling system location on the stresses
produced in die is analysed and their optimum location is determined by ANSYS. Further, filling simulation
of the modified design was carried out and minor modifications are made to optimize the filling
operation using MAGMA Software. The research work proves to be useful in increasing the die life by considering
the optimization of cooling channel position along with the gating system design in the design
stage.https://www.sciencedirect.com/science/article/pii/S2214785320389598

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