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Hétu, J.‐F.; Gao, D. M.; Kabanemi, Kalonji K.; Bergeron, Stephen Y.; Nguyen, K. T.; Loong, C.A.

doi:10.1023/a:1008686021300

Cited by 20 publications

(7 citation statements)

References 10 publications

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“…Despite this increased capability, few studies appear in the literature focused on commercial wheel production. Hetu et al developed a coupled fluid flow-heat transfer model that was used to simulate the LPDC process for an automotive housing and a wheel [6]. Another example is the model developed by Merlin et al for simulating the casting of A356 wheels [7].…”

Section: Introductionmentioning

confidence: 99%

“…The development of robust and accurate descriptions of boundary conditions describing these areas, and ultimately the overall accuracy of these models, has been undermined by the availability of high-quality, comprehensive data from the production line, which is technically challenging and expensive to acquire. For example, the studies conducted by Hetu et al [6] and Merlin et al [7] were not validated against quantitative in-process data-e.g., in-die and/or in-casting temperature data. One good example of work in which model results were compared to commercial data is the work done by Zhang et al [15], which presents a complex numerical model developed in ABAQUS TM and its validation using the temperature data acquired from an LPDC process during the production of a conventional aluminum wheel.…”

Section: Introductionmentioning

confidence: 99%

“…Heat Transfer to Environment-Heat transfer on the outer surfaces of the die to the surrounding plant environment can occur through convection and radiation. The convective heat transfer is described in Equation ( 5), while the radiative transport has been described using the Stefan-Boltzmann equation-Equation (6). The parameters related to the environmental heat transfer are given in Table 5.…”

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confidence: 99%

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Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation

Wei

Cockcroft

et al. 2020

Metals

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This manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive wheels. The model was developed in the commercial casting simulation platform ProCAST for a production die operating under production conditions. Key elements in the development of the model included the definition of the resistance to heat transfer across the die/casting interfaces and die/water-cooling channel interfaces. To examine the robustness of the modeling methodology, the model was applied to simulate production and non-production process conditions for a die cooled by a combination of water and air-cooling (Die-A), and to a second die for a different wheel geometry (Die-B) utilizing only water cooling for production conditions. In each case, the model predictions with respect to in-die and in-wheel temperature evolution were compared to industrially derived thermocouple (TC) data, and were found to be in good agreement. Once tuned to the process conditions for Die-A operating under production conditions, no further tuning of the die/casting interface resistance was applied. Additionally, the model results, in terms of the prediction of pockets of solid encapsulated liquid, were used to compare to x-ray images of wheels. This comparison indicated that the model was able to predict clusters of porosity associated with encapsulated liquid with an equivalent radius of ~27 mm.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

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Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation

Wei

Cockcroft

et al. 2020

Metals

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“…The two most important numerical methods employed in casting simulation are Finite Difference Method (FDM) and Finite Element Method (FEM). FDM is relatively easy to program and it produces results with reasonable accuracy [6][7][8], although FEM has been shown to have advantages over FDM for modeling thin-walled castings [9][10]. Recently, Smoothed Particle Hydrodynamics (SPH), a meshless method for solving physical problems governed by partial differential equations, has been used to model high pressure die casting [11].…”

Section: Introductionmentioning

confidence: 99%

“…Based on MAC the SMAC (Simplified MAC) method was developed, in which the pressure does not need be calculated [17]. The two main methods of tracking free surface during time-dependent flow are VOF and MAC [6][7][8][9][10][11][12][13][14][15][16].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation Of Filling Process In Die Casting

Li¹,

Zhou²

2003

Materials Technology

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Mould filling in high pressure die casting is a complex process where performance is governed by a number of design variables. The small heat capacity of magnesium alloys, combining with low density, results in the magnesium molten mass chilling very rapidly. This makes the modeling of filling process in magnesium die casting more important in assuring the quality of casting. In order to realize this objective, a 3-D software program using FDM is developed to simulate the filling process.This program includes a mesh generation module, a solver, a post-processor and a Graphic User Interface (GUI). SMAC method was used to solve the full Navier-Stokes equations and track the free surface, and the κ-ε model to account for the turbulence phenomenon during filling process. The simulation results were shown to be in good agreement with the experimental results.

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Modeling of As‐Cast A356 for Coupled Explicit Finite Element Analysis

Roy

Maijer

2012

Light Metals 2012

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Cited by 20 publications

References 10 publications

Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation

Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part II Modeling Methodology and Validation

Numerical Simulation Of Filling Process In Die Casting

Modeling of As‐Cast A356 for Coupled Explicit Finite Element Analysis

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