Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

Experiment and simulation of foaming injection molding of polypropylene/nano-calcium carbonate composites by supercritical carbon dioxide

Microcellular injection molding of neat isotactic polypropylene(iPP) and isotactic polypropylene/nano-calcium carbonate composites(i PP/nano-CaCO_3) was performed using supercritical carbon dioxide as the physical blowing agent. The influences of filler content and operating conditions on microstructure morphology of i PP and i PP/nano-CaCO_3 microcellular samples were studied systematically. The results showed the bubble size of the microcellular samples could be effectively decreased while the cell density increased for i PP/nano-CaCO_3 composites, especially at high CO_2 concentration and back pressure, low mold temperature and injection speed, and high filler content. Then Moldex 3D was applied to simulate the microcellular injection molding process, with the application of the measured ScCO_2 solubility and diffusion data for i PP and i PP/nano-Ca CO_3 composites respectively. For neat i PP, the simulated bubble size and density distribution in the center section of tensile bars showed a good agreement with the experimental values. However, for i PP/nano-CaCO_3 composites, the correction factor for nucleation activation energy F and the pre-exponential factor of nucleation rate f_0 were obtained by nonlinear regression on the experimental bubble size and density distribution. The parameters F and f_0 can be used to predict the microcellular injection molding process for i PP/nano-CaCO_3 composites by Moldex 3D.

Multiphase Flow and Thermo-Mechanical Behaviors of Solidifying Shell in Continuous Casting Mold

The metallurgical phenomena occurring in the continuous casting mold have a significant influence on the performance and the quality of steel product.The multiphase flow phenomena of molten steel,steel/slag interface and gas bubbles in the slab continuous casting mold were described by numerical simulation,and the effect of electromagnetic brake（EMBR） and argon gas blowing on the process were investigated.The relationship between wavy fluctuation height near meniscus and the level fluctuation index F,which reflects the situation of mold flux entrapment,was clarified.Moreover,based on a microsegregation model of solute elements in mushy zone with δ/γ transformation and a thermo-mechanical coupling finite element model of shell solidification,the thermal and mechanical behaviors of solidifying shell including the dynamic distribution laws of air gap and mold flux,temperature and stress of shell in slab continuous casting mold were described.