Two-phase flow modeling of air entrapment in high pressure die casting considering air compressibility and surface tension

2019 ◽  
Vol 190 ◽  
pp. 192-205
Author(s):  
Jing Hao ◽  
Yi Nie ◽  
Feng Ji ◽  
Limei Cha
Keyword(s):  
Surface Tension ◽  
High Pressure ◽  
Two Phase Flow ◽  
Die Casting ◽  
Phase Flow ◽  
Flow Modeling ◽  
Air Entrapment ◽  
Two Phase ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

Flow Modeling in High-Pressure Die-Casting Processes Using SPH Model

2017 ◽  
Vol 12 (1) ◽  
pp. 97-105 ◽  
Author(s):  
M. Y. Hu ◽  
J. J. Cai ◽  
N. Li ◽  
H. L. Yu ◽  
Y. Zhang ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Flow Modeling ◽  
High Pressure Die Casting ◽  
Sph Model ◽  
Pressure Die Casting

Experimental Investigation of Porosity Formation During the Slow Injection Phase in High-Pressure Die-Casting Processes

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
R. Zamora ◽  
J. J. Hernandez-Ortega ◽  
F. Faura ◽  
J. Lopez ◽  
J. Hernandez
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Three Dimensional ◽  
Casting Machine ◽  
Operating Conditions ◽  
Slow Phase ◽  
Air Entrapment ◽  
High Pressure Die Casting ◽  
Numerical Predictions ◽  
Pressure Die Casting

The air entrapment mechanisms in die-casting injection chambers that may produce porosity in manufactured parts are analyzed in this work using visualization techniques of the flow in a transparent injection chamber model, using water as working fluid. In particular, results for the free-surface profile evolution and for the volume of air remaining in the chamber at the instant at which the water begins to flow through the runner are analyzed for different maximum plunger speeds and initial filling fractions. A comparison between these visualizations and the numerical results of Zamora et al. (2007, “Experimental Verification of Numerical Predictions for the Optimum Plunger Speed in the Slow-Phase of a High-Pressure Die Casting Machine,” Int. J. Adv. Manuf. Technol., 33, pp. 266–276) which were obtained using a three-dimensional numerical model, shows a good degree of agreement. After discussing the air entrapment mechanisms that may produce porosity in manufactured parts, different experiments, which were carried out under real operating conditions using an aluminum alloy in a high-pressure die-casting machine with horizontal cold chamber, will be presented. The die-cavity geometry used in the experiments was appropriately modified to isolate the slow shot phase from the rest of the injection process, and the porosity levels in the manufactured parts were measured using a gravimetric technique. The optimum values of the maximum plunger speed that minimizes porosity in the manufactured parts have been determined. These values are very close to the previous numerical predictions of López et al. (2003, “On the Critical Plunger Speed and Three-Dimensional Effects in High-Pressure Die Casting Injection Chambers,” ASME J. Manuf. Sci. Eng., 125, pp. 529–537)

FUNDAMENTALS OF TWO-PHASE FLOW MODELING

1994 ◽  
Vol 8 (1-4) ◽  
pp. 1-67 ◽  
Author(s):  
Graham B. Wallis ◽  
Donald A. Drew
Keyword(s):  
Two Phase Flow ◽  
Phase Flow ◽  
Flow Modeling ◽  
Two Phase

A Development of Virtual Manufacturing System for Magnesium High Pressure Die Casting Processes

Materials ◽  
2003 ◽  
Author(s):  
Weilong Chen
Keyword(s):  
High Pressure ◽  
Magnesium Alloys ◽  
Die Casting ◽  
Virtual Manufacturing ◽  
Mold Design ◽  
High Pressure Die Casting ◽  
Molten Magnesium ◽  
Pressure Die Casting ◽  
Soft And Hardware ◽  
Free Magnesium

In recent years, high-pressure die-casting magnesium components have been gaining currency worldwide because of the excellent properties that magnesium alloys can offer to meet new product requirements. With the increasing application of magnesium parts worldwide, many research and development projects have been carried out to advance HPDC technology. However, truly optimized mold design and production of defect free castings remains a challenge for die casters. For many HPDC magnesium products, especially those specified for porosity-free and high cosmetic requirement, the challenge not only comes form a lack of a deeper understanding of how molten magnesium alloys fill the mold cavity and form defects, but also from improper preliminary part design. This study proposes a virtual prototyping system that integrates several effective soft and hardware tools for both the part and mold-design engineer to evaluate part manufacturability. Also, investigated in this study are the major causes of those defects that are the predominant cause of rejection of thin walled, leak-free magnesium parts requiring highly cosmetic finishes.

scholarly journals On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting

Technologies ◽  
2021 ◽  
Vol 9 (2) ◽  
pp. 39
Author(s):  
Anders E. W. Jarfors ◽  
Ruslan Sevastopol ◽  
Karamchedu Seshendra ◽  
Qing Zhang ◽  
Jacob Steggo ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Life Extension ◽  
Conformal Cooling ◽  
High Pressure Die Casting ◽  
Cooling Channels ◽  
Die Life ◽  
Die Materials ◽  
Pressure Die Casting ◽  
Semisolid Casting

Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

Failure analysis of H13 steel die for high pressure die casting Al alloy

2021 ◽  
pp. 105330
Author(s):  
Rengen Ding ◽  
Haibo Yang ◽  
Shuzhi Li ◽  
Guodong Wu ◽  
Jiahao Mo ◽  
...  
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Die Casting ◽  
Al Alloy ◽  
H13 Steel ◽  
High Pressure Die Casting ◽  
Pressure Die Casting
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