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Short shots and industrial case studies: Understanding fluid flow and solidification in high pressure die casting

机译：简要介绍和工业案例研究：了解高压压铸件中的流体流动和凝固

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摘要

The geometric complexity and high fluid speeds involved in high pressure die casting (HPDC) combine to give strongly three dimensional fluid flow with significant free surface fragmentation and splashing. A simulation method that has proved particularly suited to modelling HPDC is Smoothed Particle Hydrodynamics (SPH). Materials are approximated by particles that are free to move around rather than by fixed grids, enabling more accurate prediction of fluid flows involving complex free surface motion. Three practical industrial case studies of SPH simulated HPDC flows are presented; aluminium casting of a differential cover (automotive), an electronic housing and zinc casting of a door lock plate. These show significant detail in the fragmented fluid free surfaces and allow us to understand the predisposition to create defects such as porosity in the castings. The validation of flow predictions coupled with heat transfer and solidification is an important area for such modelling. One powerful approach is to use short shots, where insufficient metal is used in the casting or the casting shot is halted part way through, to leave the die cavity only partially filled. The frozen partial castings capture significant detail about the order of fill and the flow structures occurring during different stages of filling. Validation can occur by matching experimental and simulated short shots. Here we explore the effect of die temperature, metal super-heat and volume fill on the short shots for the casting of a simple coaster. The bulk features of the final solid castings are found to be in good agreement with the predictions, but the fine details appear to depend on surface behaviour of the solidifying metals. This potentially has significant implications for modelling HPDC.
机译：高压压铸（HPDC）涉及的几何复杂性和高流体速度相结合，产生了具有明显自由表面碎裂和飞溅的强三维流体流。事实证明，特别适合对HPDC建模的一种模拟方法是“平滑粒子流体动力学（SPH）”。通过自由移动的粒子而不是固定的网格来近似材料，从而可以更准确地预测涉及复杂的自由表面运动的流体流动。提出了三个实用的SPH模拟HPDC流量的工业案例研究；差速器盖（汽车）的铝铸件，电子壳体和门锁板的锌铸件。这些在零散的无液表面上显示了重要的细节，使我们能够理解在铸件中产生缺陷（如孔隙）的易感性。流动预测与传热和凝固相结合的验证是此类建模的重要领域。一种有效的方法是使用短铸模，其中在铸件中使用的金属不足，或者铸模中途停止铸模，从而仅部分填充型腔。冻结的局部铸件捕获了有关填充顺序和在不同填充阶段出现的流动结构的重要细节。可以通过匹配实验和模拟短镜头来进行验证。在这里，我们探讨了模具温度，金属过热度和填充量对铸造简单杯垫的短镜头的影响。发现最终的固体铸件的整体特征与预言相吻合，但是细小的细节似乎取决于凝固金属的表面行为。这可能会对HPDC建模产生重大影响。

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  • 来源
    《Applied Mathematical Modelling》 |2010年第8期|p.2018-2033|共16页
  • 作者

    Paul W. Geary; Joseph Ha; Mahesh Prakash; Thang Nguyen;

  • 作者单位

    CSIRO Mathematical and Information Sciences, Private Bag 33, Clayton South, Vic 3169, Australia;

    rnCSIRO Mathematical and Information Sciences, Private Bag 33, Clayton South, Vic 3169, Australia;

    rnCSIRO Mathematical and Information Sciences, Private Bag 33, Clayton South, Vic 3169, Australia;

    CSIRO Materials Science and Engineering, Private Bag 33, Clayton South, Vic 3169, Australia;

  • 收录信息 美国《科学引文索引》(SCI);美国《工程索引》(EI);
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

    high pressure die casting; SPH; solidification; short shot; fluid flow; casting defects;

    机译：高压压铸;SPH;凝固;短射;流体流量铸造缺陷;

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