On the CFD Modelling of Slamming of the Metal Melt in High-Pressure Die Casting Involving Lost Cores

This paper uses computational fluid dynamics (CFD), in the form of OpenFOAM software package, to investigate forces on salt core high-pressure die casting (HPDC) when being exposed impact inflowing melt filling stage, with particular respect moment first impact—commonly known as slamming. The melt-air system is modelled via an Eulerian volume-of-fluid approach, treating air a compressible perfect gas. turbulence treated Reynolds-averaged Navier Stokes (RANS) approach. RNG k-ε and Menter SST k-ω models are both evaluated, use latter ultimately adopted for batch computations. A study effect Courant number, view establishing mesh independence, indicates that meshes which finer, time steps smaller, than those previously employed HPDC simulations required capture slamming properly, existing analytical empirical measurements. As second step, it then discussed what response should be expected this force, its spike-like morphology small force-time integral, impacts core. It found displacement due spike force so that, even though high value, bending stress inside remains below critical limit fracture. can therefore concluded assuming homogeneous crack-free material conditions, not failure-critical.