INTRODUCTION CHAPTER 1
CHAPTER 1
INTRODUCTION
High-pressure die casting (HPDC) is an important process for
manufacturing high-volume and low-cost components. The geometric complexity of dies
leads to strong 3D fluid flow with significant free surface fragmentation and splashing
[1]. Computational fluid dynamics (CFD) is the technique of solving the governing
equations of fluid motion and other related phenomena using a computer. Accurate
representation of the coupled effects between turbulent fluid flow with a free surface,
heat transfer, solidification, and mold deformation has been shown to be necessary for the
realistic prediction of several defects in casting [2]. Porosity is one of the major defects
in a casting which results in the decrease of the mechanical properties, in particular
fatigue and ultimate tensile strength [3]. Micro porosity formation is based on two main
phenomenons, pressure drop in the mushy zone and segregation of gas bubbles
(cavitation) [4]. E.F. Brush et al (2003) have reported on the results of an investigation to
minimize and control the distribution of porosity in edge gated copper rotor die casting.
[5]. [Link] (2003) speaks about the improper solidification of the molten material
which leads to defects like shrinkage and micro-porosity, which prevents the metal from
performing its intended function [6]. Bounds et al proposed a model for macro defect
predictions based on the coupling of free surface flow, heat transfer and solidification [7].
By varying the geometry of the mold cavity (and gating systems), casting conditions, and
physical properties of the liquid and mold, their effect can easily be assessed [8].
CFD is concerned with obtaining numerical solution to fluid flow problems by
using computers. The temperature distribution across the melt and the mold, local cooling
rate, filling rate, and velocity pattern in the mold are mutually coupled by the design of
gating system [9]. This paper deals with the designing of gating system for rock rail
assembly. It is manufactured by cold chamber die casting. It is made of aluminium Al
384 alloy which has a melting range of 516-582 degree Celsius. Gates and runners were
designed using the software DIEDIFICE. The inputs for the DIEDIFICE such as volume,
discharge, gate area and gate length were obtained using the software gate area
application developed by the company itself. This study has been carried out with the
commercial code FLOW-3D (Flow Science Inc., Los Alamos, NM), that uses a finite-
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INTRODUCTION CHAPTER 1
difference method to solve the complete Navier–Stokes equations for the laminar-flow
regime. It produce accurate results and visualizes the casting defects encountered such as
air porosity, voids formation, premature solidification etc. Many design alternatives of
gates and runner was simulated using FLOW3D until a defect free casting was obtained.
The finalized design of gates and runners was tested in a 650 ton die casting machine and
the casting obtained was sound with good quality and was defect free.