Assessment of Computer Simulation Software and Process Data for High Pressure Die Casting of Magnesium

Sabau, Adrian S¹  Hatfield, Edward C¹  Dinwiddie, Ralph Barton¹  Kuwana, Kazunori²  Viti, Valerio³  Hassan, Mohamed I³  Saito, Kozo⁴ 

[1] ORNL;University of Kentucky;University of Kentucky, Lexington;University

关键词: ATOMIZATION;    CASTING;    COMPUTERIZED SIMULATION;    COMPUTERS;    DEFECTS;    DESIGN;    DISTRIBUTION;    GRAPHITE;    HEAT FLUX;    HEAT TRANSFER;    LUBRICANTS;    MAGNESIUM;    SIMULATION;    SOLIDIFICATION;    VALIDATION;    WATER;   

DOI  :  10.2172/932142
RP-ID  :  ORNL/TM-2007/041
PID  :  OSTI ID: 932142
Others  :  Other: VT0502010
Others  :  CEVT024
Others  :  TRN: US200813%%436

学科分类：材料科学（综合）

美国|英语

来源: SciTech Connect

【 摘 要 】

Computer software for the numerical simulation of solidification and mold filling is an effective design tool for cast structural automotive magnesium components. A review of commercial software capabilities and their validation procedures was conducted. Aside form the software assessment, the program addressed five main areas: lubricant degradation, lubricant application, gate atomization, and heat transfer at metal mold interfaces. A test stand for lubricant application was designed. A sensor was used for the direct measurement of heat fluxes during lubricant application and casting solidification in graphite molds. Spray experiments were conducted using pure deionized water and commercial die lubricants. The results show that the sensor can be used with confidence for measuring heat fluxes under conditions specific to the die lube application. The data on heat flux was presented in forms suitable for use in HPDC simulation software. Severe jet breakup and atomization phenomena are likely to occur due to high gate velocities in HPDC. As a result of gate atomization, droplet flow affects the mold filling pattern, air entrapment, skin formation, and ensuing defects. Warm water analogue dies were designed for obtaining experimental data on mold filling phenomena. Data on break-up jet length, break-up pattern, velocities, and droplet size distribution were obtained experimentally and was used to develop correlations for jet break-up phenomena specific to die casting gate configurations.