Gravity die casting is a process wherein the fluid metal is poured into metallic moulds without application of any external force. The fluid metal enters the cavity by gravity method. In the design of dies for GDC, usage of “cores” is an important issue. The undercuts and the hollow shapes are produced with the help of additional mould parts called “cores”. For simple shapes without any under cuts the metallic cores could be used, whereas for undercuts and complex hollow shapes, which are difficult to retract, sand or plaster of Paris cores are employed. The gravity die casting process is required for huge volume production of non ferrous alloy castings of aluminum, magnesium, copper and zinc base alloys and to limited extent for cast iron castings. Castings can be produced by operation of dies manually or by automatic devices or through die casting machines based on the body of production. The die materials used are gray cast iron and steels. The GDC process is ensuring to achieving 20% higher mechanical properties than that of a sand casting because of quick rate of solidification imparting better grain size. The process can be automated and also can produce semi-gravity die-castings using sand or plaster of paris cores for production of interior details. In this study the Housing casting part produced were defective due to improper gating design, riser design, air entrapment, cold metal, etc. Using Advanced Simulation Software I have analyzed the problems existing and implemented such that defect free and quality castings are produced. The process is implemented to get good quality and defect free casting. Keywords: die casting, GDC process, grain size, cores
