Particle Method Simulation for Formation and Flow of Cold Flakes in High-Pressure Die Casting
- 10 Downloads
In high-pressure die casting (HPDC) processing of aluminum alloys, solidified layers generated in the sleeve of a die casting machine that flow into the mold cavity are known as “cold flakes.” The prediction and control of them are a crucially important issue for HPDC. This study developed a method to simulate their formation and flow using smoothed particle hydrodynamics. First, a solidified layer was modeled as a set of solid particles with behaviors defined by mechanical constitutive equations. Second, this study proposed an algorithm for ascertaining the phase of particles and for calculating liquid–solid particle interaction. Numerical results demonstrated that the method can predict the formations of solidified layers in the sleeve, their peeling and folding during the plunger movements, their inflow into the runner and the mold cavity, and flow disturbances caused by solidified layers trapped at the gate.
Keywordscold flakes high-pressure die casting HPDC particle method smoothed particle hydrodynamics SPH AISI 383.0 (JIS ADC12) aluminum alloy
The authors thank Prof. Makoto Yoshida of Waseda University for his valuable advice and Prof. Naomi Nishi of Institute of Technologists for providing a picture of cold-flake defect.
- 2.H. Mao, A Numerical Study of Externally Solidified Products in the Cold Chamber Die Casting Process, Ph.D. Dissertation, The Ohio State University (2004)Google Scholar
- 3.Y. Maeda, H. Nomura, Numerical experiment of cold flakes behavior in shot sleeve of aluminum alloy die casting. J. Jpn. Foundry Eng. Soc. 78(12), 654–660 (2006). (in Japanese) Google Scholar
- 7.M. Kazama, T. Suwa, Numerical Simulation of the Solidification of the Melted Metal by the Particle Method, in Proceedings of WCCM XI—ECCM V—ECFD VI, Barcelona (2014)Google Scholar
- 8.M. Ichimiya, Y. Sakai, Development of filling and solidification simulation using smoothed particle hydrodynamics. J. Jpn. Foundry Eng. Soc. 85(8), 481–488 (2013). (in Japanese) Google Scholar
- 9.N. Hirata, K. Anzai, Heat transfer and solidification analysis using particle method. J. Jpn. Foundry Eng. Soc. 80(2), 81–87 (2008). (in Japanese) Google Scholar
- 12.K. Iwashita, M. Hakuno, Modified distinct element method simulation of dynamic cliff collapse, in Structural Engineering/Earthquake Engineering (Proceedings of JSCE No. 416), vol. 7 (1), pp. 133–142 (1990)Google Scholar