Wave Behavior caused by Ladle Pouring and Plunger Advancing in Aluminum Alloy Die Casting using Particle-Based SPH Method

                                
==Abstract==

Casting CAE software determines the operating conditions of ladle pouring and plunger advancing and prevents defects in aluminum alloy die casting. Quick operations of the ladle pouring and plunger advancing lead to disturbance of the molten metal flow and increase the risk of air entrapment. Conversely, if these operations are performed slowly, the temperature of the molten metal drops, and the risk of cold flake formation increases. Furthermore, since an oxide film exists on the surface of molten aluminum alloy and flows differently from water, it is necessary to perform simulations considering the oxide film. In conventional casting CAE simulation, the flow behavior by the plunger advancing is often simulated from a state in which the molten metal is stationary in the sleeve. In this study, we numerically analyze wave behavior caused by ladle pouring and plunger advancing processes. One is the superimposed ones of wave behavior when ladle pouring and plunger advance processes are simulated separately. The other is the wave behavior when simulated as a series of processes. The casting analysis software “COLMINA CAE” by the particle-based SPH method, which is considered the oxide film of molten aluminum alloy, is used to analyze the wave behaviors. Further, they have verified the wave behavior through visualization experiments. Comparing the simulated wave height and velocity, which shows the wave motion generated when the plunger advances from the stationary state of the molten metal in the sleeve is different from the wave motion in a series of processes, suggesting the need for simulation of a series of processes. These trends of wave behavior obtained in the simulation are similar to that of the actual phenomenon. Therefore, the present simulation