材料期刊网

通过对压铸充型过程中卷气缺陷形成机理的分析,认为型腔中空气的流动以及与金属液之间的相互作用是形成卷气现象的主要原因.为了考虑型腔中空气的流动,采用了一种不可压缩两相流数学模型来模拟压铸充型过程的卷气现象.通过计算流体力学中的两个基准算例,较为全面地验证了该模型的准确性和可靠性.在此基础上,设计了专门针对压铸充型过程的高速水模拟实验,通过对可视化实验结果与两相流模拟结果的比较,证实二者吻合较好,说明了该模型能够较好地模拟液体的充填行为和卷入其中的气泡.

The most common defect found in high pressure die casting (HPDC) process is the gas porosity which significantly affects the mechanical properties of the final components. The generation of gas porosity is known mainly due to the air entrapment in the liquid metal during the mold filling stage. Knowing the trapped-air location and amount could allow for a more accurate and objective analysis of casting quality. In the past few decades, extensive efforts have been made to develop simulation codes of casting flow. Most of these codes solve the velocity, pressure and fluid fraction only in the liquid phase with the assumption that the effect of air in the die cavity is negligible. As a matter of fact, the air in the die cavity has significant influence on the filling pattern of the molten metal and the gas porosity distribution of the die casts. Recently, following the development of computational fluid dynamics (CFD), two-phase flow models have drawn continuous attention in the numerical simulation of casting processes, but there are still few models and further studies are needed. In this study, the mechanism of the formation of air entrapment defects in the HPDC process was discussed and it turned out that the air flow in the die cavity as well as the interaction between air and liquid metal resulted in the final air entrapment. In order to consider the air flow in the die cavity, an incompressible two-phase flow model was presented to simulate the air bubbles entrapped by the free surface of liquid metal during the mold filling stage. Two numerical benchmark tests of fluid dynamics were performed to verify the validity and stability of the model. Furthermore, a high speed water analog experiment similar to real die casting process was designed and carried out to compare the experimental results with the simulation ones. Good agreements obtained demonstrate that the two-phase flow model has acceptable prediction accuracy in modeling the filling behavior of liquid and tracking the entrapped air bubbles.