Simulation of mold filling and prediction of gas entrapment on practical high pressure die castings

Element parameters including volume filled ratio, surface dimensionless distance, and surface filled ratio for DFDM （direct finite difference method） were proposed to describe shape and location of free surfaces in casting mold filling processes. A mathematical model of the filling process was propo...

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Bibliographic Details
Published in:Transactions of Nonferrous Metals Society of China 2010-11, Vol.20 (11), p.2064-2070
Main Author: 赵海东 白砚飞 欧阳晓贤 董普云
Format: Article
Language:English
Subjects:
Die casting
Entrapment
Finite difference method
gas entrapment
high pressure die casting
Mathematical analysis
Mathematical models
mold filling
Molds
Porosity
Pressure die casting
Tracking
数学模型
表面形状
铸件充型
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Summary:Element parameters including volume filled ratio, surface dimensionless distance, and surface filled ratio for DFDM （direct finite difference method） were proposed to describe shape and location of free surfaces in casting mold filling processes. A mathematical model of the filling process was proposed specially considering the mass, momentum and heat transfer in the vicinity of free surfaces. Furthermore, a method for gas entrapment was established by tracking flow of entrapped gas. The model and method were applied to practical ADC1 high pressure die castings. The gas entrapment prediction was compared with the fraction and maximum size of porosities in the different casting parts. The comparison shows validity of the proposed model and method. The study indicates that final porosities in high pressure die castings are dependent on both gas entrapment during mold filling process and pressure transfer within solidification period.
ISSN:1003-6326
DOI:10.1016/S1003-6326(09)60418-0