Atomization in High-Pressure Die Casting - Step 2 Simulation of Atomized Flow of Molten Aluminum by LES-VOF Method

Eitaro Koya, Masahiko Nakagawa, Shinya Kitagawa, Jun Ishimoto, Yoshikatsu Nakano, Naoya Ochiai

Research output: Contribution to journalConference articlepeer-review

1 Citation (Scopus)

Abstract

The atomization of molten aluminum when injected during high-pressure die casting is analyzed to determine its effect in enhancing the strength of the product being cast. In the previously reported first step of this study, molten aluminum was injected into open space and its atomization was observed photographically. Now in the second step of the study, a simulation is conducted to determine how the molten aluminum becomes atomized at the injection nozzle (gate) and how this atomized material flows and fills the cavity. A new simulation method is developed based on large-eddy simulation coupled with the volume-of-fluid method. The simulation system is verified by comparing its output with photographs taken in the first step of the study. Simulations are then conducted using an approximation of a real cavity to visualize how it is filled by the atomized molten aluminum. The results show that the atomized material is conveyed through the cavity as a multiphase flow containing fine air bubbles, and that this multiphase flow persists until filling is complete.

Original languageEnglish
JournalSAE Technical Papers
Volume2018-April
DOIs
Publication statusPublished - 2018 Jan 1
Event2018 SAE World Congress Experience, WCX 2018 - Detroit, United States
Duration: 2018 Apr 102018 Apr 12

ASJC Scopus subject areas

  • Automotive Engineering
  • Safety, Risk, Reliability and Quality
  • Pollution
  • Industrial and Manufacturing Engineering

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