Skip to main content
SpringerLink
Log in

Effects of Shot Sleeve Filling on Evolution of the Free Surface and Solidification in the High-Pressure Die Casting Machine

  • Published:
International Journal of Metalcasting Aims and scope Submit manuscript

Abstract

High-pressure die casting (HPDC) is one of the most important manufacturing processes. The air entrapment caused by the liquid metal flow in the slow shot phase of HPDC in a horizontal cold chamber is one of the factors that contribute to the porosity defect of die castings. The pouring of molten metal into the shot sleeve of a HPDC resembles gravity pour die casting. This stage did not receive much attention in the die casting research because it is believed that it does not play a significant role. The shot sleeve filling time depends on the amount of metal being poured and is in the range of 1–8 s. Furthermore, a common foundry practice in aluminum HPDC is to let the metal settle for a few seconds, to allow for any air bubbles to escape from the melt. This paper examines the influence of shot sleeve filling on evolution of the free surface and solidification in the HPDC machine. The numerical simulation of the free surface and solidification during the two-dimensional flow of aluminum in the horizontal cylinder and mold fillings of the HPDC machine with cold chamber was developed. The developed numerical model is based on the conservation equations of mass, momentum and energy. The moving boundary condition of the plunger movement in the injection process was considered. The tracking of the free surface is ensured by the volume of fluid (VOF) method. The enthalpy method is employed to solve the phase change heat transfer problem in the solidification process. The study examines the influence of the shot sleeve filling, the fraction filling and the time of metal settle on the evolution of the interface aluminum liquid–air profile, the mass of air imprisoned, the velocity magnitude and the temperature contours versus time.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20

Similar content being viewed by others

References

  1. F. Faura, J. Lopez, J. Hernandez, On the optimum plunger acceleration law in the slow shot phase of pressure die casting machines. Int. J. Mach. Tools Manuf 41(2), 173–191 (2001)

    Article  Google Scholar 

  2. L. Yuan, S. Xiong, B. Liu, M. Masayuki, M. Yoshihide, I. Shingo, Numerical simulation and optimization of liquid metal flow in the shot sleeve of cold chamber die casting process. In, Charles-André G, Michel B (eds) Modeling of casting, welding and advanced solidification processes-XI (2006)

  3. T.H. Han, J.H. Kuo, W.S. Hwang, numerical simulation of the liquid-gas interface shape in the shot sleeve of cold chamber die casting machine. J. Mater. Eng. Perform. 16(5), 521–526 (2007)

    Article  Google Scholar 

  4. Y.B. Lui, W.B. Lee, B. Ralph, A reclassification of the die-filling stages in pressure die-casting processes. J. Mater. Proc. Technol. 57, 259–265 (1996)

    Article  Google Scholar 

  5. S. Sulaiman, A.M.S. Hamouda, D.T. Gethin, Experimental investigation for metal-filling system of pressure die casting process on a cold chamber machine. J. Mater. Process. Technol. 119, 268–272 (2001)

    Article  Google Scholar 

  6. R. Zamora, F. Faura, J. López, J. Hernández, Experimental verification of numerical predictions for the optimum plunger speed in the slow phase of a high-pressure die casting machine. Int. J. Adv. Manuf. Technol. 33, 266–276 (2007)

    Article  Google Scholar 

  7. A.J. Nikroo, M. Akhlaghi, M.A. Najafabadi, Simulation and analysis of flow in the injection chamber of die casting machine during the slow shot phase. Int. J. Adv. Manuf. Technol. 41, 31–41 (2009)

    Article  Google Scholar 

  8. P.W. Cleary, J. Ha, M. Prakash, T. Nguyen, Short shots and industrial case studies, Understanding fluid flow and solidification in high pressure die casting. Appl. Math. Model. 34, 2018–2033 (2010)

    Article  Google Scholar 

  9. L. Lavtar, M. Petric, J. Medved, B. Taljat, P. Mrvar, Simulations of the shrinkage porosity of Al-Si-Cu automotive components. Mater. Technol. 46, 177–180 (2012)

    Google Scholar 

  10. O. Yukio, Experimental verification and accuracy improvement of gas entrapment and shrinkage porosity simulation in HPDC process. Mater. Trans. 55(1), 154–160 (2014)

    Article  Google Scholar 

  11. H. Ahuett-Garza, Allen Miller R., The effects of heat released during fill on the deflections of die casting dies. J. Mater. Proc. Technol. 142, 648–658 (2003)

    Article  Google Scholar 

  12. H.I. Laukli, L. Arnberg, O. Lohne, Effects of grain refiner additions on the grain structures in HPDC A356 castings. Int. J. Cast Met. Res. 18, 65–72 (2005)

    Article  Google Scholar 

  13. R. Helenius, O. Lohne, L. Arnberg, H.I. Laukli, The heat transfer during filling of a high-pressure die-casting shot sleeve. Mater. Sci. Eng. A 413, 52–55 (2005)

    Article  Google Scholar 

  14. A.I.N. Korti, S. Abboudi, Numerical simulation of the interface molten metal air in the shot sleeve chamber and mold cavity of a die casting machine. Heat Mass Transfer 47, 1465–1478 (2011)

    Article  Google Scholar 

  15. A.I.N. Korti, M.C. Korti, S. Abboudi, Thermal effect in minimizing air entrainment in the 3D shot sleeve during injection stage of the HPDC machine. Int. J. Fluid Mech. Res. 43(1), 1–17 (2011)

    Article  Google Scholar 

  16. H. Bakemeyer, Operating the die casting machine, North American Die Casting Association NADCA, (2008)

  17. L. Wang, T. Nguyen, M. Murray, Simulation of flow pattern and temperature profile in the shot sleeve of high pressure die casting process, Die casting in the 21st century October 29—November 1 Cincinnati Ohio (2001)

  18. D.L. Youngs, Time-dependent multi-material flow with large fluid distortion, in Time-dependent multi-material flow with large fluid distortion, ed. by K.W. Morton, M.J. Baines (Academic Press, New York, 1982), pp. 273–285

    Google Scholar 

  19. W.J. Rider, D.B. Kothe, Reconstructing volume tracking. J. Comp. Phys. 141, 112–152 (1998)

    Article  Google Scholar 

  20. V.R. Voller, C.R. Swaminathan, B.G. Thomas, Fixed grid techniques for phase change problems, a review. Int. J. Numer. Methods Eng. 30, 875–898 (1990)

    Article  Google Scholar 

  21. A.I.N. Korti, Y. Khadraoui, A numerical simulation of the DC continuous casting using average heat capacity. Scand. J. Metall. 33, 347–354 (2004)

    Article  Google Scholar 

  22. A.N. Korti, Y. Khadraoui, Simulation numérique du transfert thermique incluant l’ébullition nucléée lors de la coulée continue des métaux. Mécanique et Industries 7, 29–37 (2006)

    Article  Google Scholar 

  23. I.L. Hans, High-pressure die casting of aluminium and magnesium alloys- grain structure and segregation characteristics, Thesis Norwegian University of Science and Technology (NTNU) Trondheim April, (2004)

  24. Z. Guo, S. Xiong, B. Liu, L. Mei, A. John, Determination of the heat transfer coefficient at metal–die interface of high pressure die casting process of AM50 alloy. Int. J. Heat Mass Transf. 51, 6032–6038 (2008)

    Article  Google Scholar 

  25. L. Lopez, J. Hernandez, F. Faura, G. Trapaga, Shot sleeve wave dynamics in the slow phase of die casting injection. ASME J. Fluids Eng. 122(2), 349–356 (2000)

    Article  Google Scholar 

  26. S.J.K. Bukhari, M.H.K. Siddiqui, Characteristics of air and water velocity fields during natural convection. Heat Mass Transf. 43, 415–425 (2007)

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. ETAP Laboratory, Department of Mechanics, FT, University of Tlemcen, BP 230, 13000, Tlemcen, Algeria

    Abdel Illah Nabil Korti

  2. Laboratoire, IRTES-M3M, Département GMC, Site de Sévenans, UTBM, 90000, Belfort Cedex, France

    Said Abboudi

Authors
  1. Abdel Illah Nabil Korti
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Said Abboudi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Abdel Illah Nabil Korti.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Korti, A.I.N., Abboudi, S. Effects of Shot Sleeve Filling on Evolution of the Free Surface and Solidification in the High-Pressure Die Casting Machine. Inter Metalcast 11, 223–239 (2017). https://doi.org/10.1007/s40962-016-0051-5

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40962-016-0051-5

Keywords

Search

Navigation