# Layout Design and Die Casting Using CAE Simulation for Household Appliances
## 1 Introduction  
Due to the development and industrialization of science and technology, aluminum alloys have developed in various fields. Due to recent problems involving resource shortage, energy conservation, and environmental problems, the manufacturing of cast iron and sand castings are being replaced by processes such as aluminum and high-pressure die casting (HPDC) [1, 2].  
Die-casting technology is an economical mass production technology that can manufacture complex parts at once and is a critical manufacturing technology in consumer goods manufacture. Its high dimensional stability and usefulness for mass production mean that it is gaining popularity as an optimal method for industries such as automotive parts and electronic components that require competitive high quality, low cost, and short delivery time. However, die-casting requires more advanced mold-making techniques due to the high temperature of the melt, high pressure on the mold surface, and the complexity and precision of the product shape [3, 4].  
CAE technology, widely applied in industrial sites, is widely used in the die-casting industry to address this problem. Generally, when manufacturing die-casting molds, theyare designed taking into consideration the layout of the molds and relationship with the extruders as well as the casting conditions, the design of the gating system, and the cooling conditions of the molds. Additionally, the degree and location of product defects caused by the casting process depends on the various casting methods. Recently, the advancement of CAE technology has dramatically reduced the existing trial-and-error process of creating casting molds. As a result, mold makers can produce high-quality casting parts, and production cost and time have been reduced [5; 6; 7; 8; 9].  
Various casting process analyses have been constructed using CAE technology. A thin-walled notebook housing with less than 1 mm thickness was investigated using computational solidification simulation [10]. The formability of bipolar plates for fuel cells was analyzed using computational filling behavior and solidification [11]; the castability of the optimized geometry, the absence of defects, and the local mechanical properties were verified and calculated using MAGMA software [12]. The various analyses for the optimal process design of an automobile gear housing was performed using filling behavior and solidification with MAGMA software [13]. The LPDC process parameters of a thin-walled component with less than 1.5 mm thickness were optimized using numerical simulation [14]. By using a computer-aided parametric design, the semi-automated design of a gating system was investigated to address the problem of the automatic generation of the gating elements and to utilize design evaluation [15].  
In this study, CAE technology quickly and accurately predicts the filling and solidification processes during casting and establishes sound methods with reduced production costs. A cooking grill is a kitchen cooking utensil with a light weight and high thermal conductivity of ADC 12 types. Using CAE simulation software (AnyCasting, Seoul, Korea), three casting methods were reviewed to minimize the internal air porosities of castings and ensure quality stability. The aims were to analyze the mold filling and solidification processes in order to establish a defect control method and derive the optimal casting method for the die-casting mold design and fabrication process.