Skip to main content
SpringerLink
Log in

Numerical modeling of splashing and air entrapment in high-pressure die casting

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

High-pressure die casting (HPDC) is one of the most important manufacturing processes. Air porosity in HPDC parts has many serious effects upon the casting quality. A 3D single-phase code based on the SOLA-VOF algorithm is used for the continuous phase advection during mold filling. In this research, a computational model based on concentration transport equation is used for calculation of air porosity distribution and a mixed VOF-Lagrange algorithm is developed in order to model splashing in HPDC. Finally, Schmid’s experimental tests are used to verify the modelling results and the comparison between the experimental data and simulation results has shown a good agreement.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Cleary PW, Ha J, Prakash M, Nguyen T (2006) 3D SPH flow predictions and validation for high-pressure die casting of automotive components. Appl Math Model 30(11):1406–1427

    Article  Google Scholar 

  2. Schmehl R, Maier G, Wittig S (2000) CFD analysis of fuel atomization, secondary droplet breakup and spray dispersion in the premix duct of a LPP combustor. Eighth International Conference on Liquid Atomization and Spray Systems, ICLASS 2000, Pasadena, CA, USA, July

  3. Mundo C, Somerfeld M (1995) Droplet-wall collisions, experimental studies of the deformation and breakup process. Int J Multiphase Flow 21:151–173

    Article  MATH  Google Scholar 

  4. Karl A, Rieber M, Schelkle M, Anders K, Frohn A (1996) Comparison of new numerical results for droplet wall interactions with experimental results. Proceedings of the ASME Fluids Engineering Summer Meeting, FED-236:201–206

  5. Issa RJ (2003) Numerical modeling of the dynamics and heat transfer of impacting sprays for a wide range of pressures. PhD Dissertation, University of Pittsburgh

  6. Attar E, Homayonifar P, Babaei R, Davami P (2005) Modeling of air pressure effects in casting molds. Model Sim Mater Sci Eng 13:903–917

    Article  Google Scholar 

  7. Lee SG, Gokhale AM, Patel GR, Evans M (2006) Effect of process parameters on porosity distributions in high-pressure die-cast AM50 Mg-alloy. Mater Sci Eng A 427:99–111

    Article  Google Scholar 

  8. Kim SW, Turng LS (2004) Developments of three-dimensional computer-aided engineering simulation for injection moulding. Model Sim Mater Sci Eng 12:S151–S173

    Article  Google Scholar 

  9. Tavakoli R, Babaei R, Varahram N, Davami P (2006) Numerical simulation of liquid/gas phase flow during mold filling. Comput Methods Appl Mech Eng 196:697–713

    Article  MATH  Google Scholar 

  10. Rider WJ, Kothey DB (1998) Reconstructing volume tracking. J Comput Phys 141:112–152

    Article  MATH  MathSciNet  Google Scholar 

  11. Nichols BD, Hirt CW, Hotchkiss, RS (1980) SOLA-VOF: a solution algorithm for transient fluid flows with multiple free boundaries. Tech Rep LA 8355, Los Alamos, Scientific library of University of California

  12. Duff ES (1999) Fluid flow aspect of solidification modeling: simulation of low pressure die casting. PhD Thesis, Department of Mining & Metallurgical Engineering, University of Queensland

  13. Sicilian JM, Hirt CW (1985) HYDR-3D: a solution algorithm for transient 3D flows, Rep. FSI-84-00-3, Flow Science Int., Los Alamos

  14. Babaei R, Abdollahi J, Homayonifar P, Varahram N, Davami P (2006) Improved advection algorithm of computational modeling of free surface flow using structured grids. Comput Methods Appl Mech Eng 195(7/8):775–795

    Article  MATH  Google Scholar 

  15. Shahinfar S, Babaei R, Davami P (2005) 3-D simulation of mold filling with k-ɛ turbulence modeling 14th IASTED Int. Conf on Applied Simulation and Modeling, June

  16. Launder BE, Spalding DB (1974) The numerical computation of turbulent flow. Comput Methods Appl Mech Eng 3:269–289

    Article  MATH  Google Scholar 

  17. Schmid M, Klein F (1995) Fluid flow in die cavities - experimental and numerical simulation. Proc North American Die Casting Assoc Conf, Indianapolis, IN, pp 93–99

  18. Rosindale I, Davey K (1998) Steady-state thermal model for the hot chamber injection system in the pressure die casting process. J Mater Process Technol 83:27–45

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Sharif University of Technology, Tehran, Iran, P.O. Box 11365-9567

    P. Homayonifar

  2. Razi Metallurgical Research Center, Tehran, Iran

    R. Babaei, E. Attar & S. Shahinfar

  3. Department of Material Science and Engineering, Sharif University of Technology, Tehran, Iran

    P. Davami

Authors
  1. P. Homayonifar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. R. Babaei
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. E. Attar
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. S. Shahinfar
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. P. Davami
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. Homayonifar.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Homayonifar, P., Babaei, R., Attar, E. et al. Numerical modeling of splashing and air entrapment in high-pressure die casting. Int J Adv Manuf Technol 39, 219–228 (2008). https://doi.org/10.1007/s00170-007-1214-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-007-1214-6

Keywords

Search

Navigation