In another tip, we cited the advantages and disadvantages of using the hog-out process for prototyping parts to be produced in the die cast process. As noted there are pros and cons to every process.
One of the advantages to using the hog-out prototyping process is that there is no tooling involved. Changes in the prototype design are more easily accommodated by re-programming the machine making the part.
If testing the prototype for mechanical strength is vital, then note that hog-out parts tend to be stronger than cast parts. This could misrepresent the mechanical strength of the die cast part. Simulating fillets has an effect on the strength of the entire component, depending upon the location of the stresses and loads in the part design.
When testing for heat transfer in the hog-out prototype, keep in mind that the presence of draft can change the volume of mass of the part and thus skew the heat transfer test results. If you have your part made by a machine shop as a hog-out, the shop may or may not include the draft angles in the prototype. Including the draft angles, fillets and radii, which are inherent in the cast part, makes it more difficult to machine the prototype as opposed to machining the part with straight up-and-down walls. But eliminating the draft, fillets and radii in the hog-out prototype will result in an inaccurate simulation of the die cast part.
Additionally, be aware that the material used to produce the hog-outs might have different heat transfer characteristics than the material used to create the production part in the die cast process.
In the final analysis the selection of the prototyping process should not be based on what is expedient, but which process will simulate the desired characteristics of the die cast component most accurately.