Development of a 3D Filling Model of Low-Pressure Die-Cast Aluminum Alloy Wheels

A two-phase computational fluid dynamics model of the low-pressure die-cast process for the production of A356 aluminum alloy wheels has been developed to predict the flow conditions during die filling. The filling model represents a 36-deg section of a production wheel, and was developed within the...

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Bibliographic Details
Published inMetallurgical and materials transactions. A, Physical metallurgy and materials science Vol. 44; no. 12; pp. 5304 - 5315
Main Authors Duan, Jianglan, Maijer, Daan, Cockcroft, Steve, Reilly, Carl
Format Journal Article Conference Proceeding
LanguageEnglish
Published Boston Springer US 01.12.2013
Springer
Springer Nature B.V
Subjects
Aluminum alloys
Applied sciences
Characterization and Evaluation of Materials
Chemistry and Materials Science
Exact sciences and technology
Fluid dynamics
Materials Science
Metallic Materials
Metallurgy
Metals. Metallurgy
Nanotechnology
Structural Materials
Surfaces and Interfaces
Symposium: Defects and Properties of Cast Metals
Thin Films
Pressure Boundary Condition
Vertical Symmetry Plane
Free Surface
Momentum Source Term
Free Surface Position
Development
Foundry
Modeling
Low pressure
Cast alloy
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Summary:A two-phase computational fluid dynamics model of the low-pressure die-cast process for the production of A356 aluminum alloy wheels has been developed to predict the flow conditions during die filling. The filling model represents a 36-deg section of a production wheel, and was developed within the commercial finite-volume package, ANSYS CFX, assuming isothermal conditions. To fully understand the behavior of the free surface, a novel technique was developed to approximate the vent resistances as they impact on the development of a backpressure within the die cavity. The filling model was first validated against experimental data, and then was used to investigate the effects of venting conditions and pressure curves during die filling. It was found that vent resistance and vent location strongly affected die filling time, free surface topography, and air entrainment for a given pressure fill-curve. With regard to the pressure curve, the model revealed a strong relation between the pressure curve and the flow behavior in the hub, which is an area prone to defect formation.
ISSN:1073-5623
1543-1940
DOI:10.1007/s11661-013-1654-6