Flow Modeling in High-Pressure Die-Casting Processes Using SPH Model

Advances in modeling of casting processes using smoothed particle hydrodynamics (SPH) are described. Three-dimensional simulations of high-pressure die casting (HPDC) are presented for a realistic die. Developments needed for both visualization of these systems and for their simulation are described. Comparison of SPH simulations with experimental results from polishing plate is made for HPDC. The SPH comparisons are particularly good, with the method able to capture the fine details of the free surface motion, including plume shape, frequency and phase of oscillation and the correct relative heights of all the free surfaces. And these results together combine to demonstrate that SPH modeling of HPDC has now reached a level where the design of mold can be performed in a reasonable computation time for large-scale automotive castings and provide a high degree of predictive accuracy.