The air entrainment model in FLOW-3DCast is used to estimate the amount of entrained air occurring in metal casting systems, such as gravity-poured casting processes. It is based on simple physical mechanisms, which means it can also be used to estimate the amount of entrained air occurring in metal casting systems, such as gravity-poured casting processes. Recent additions of even more physical details in the model allow entrained air, which is assumed to be in the form of bubbles, to be modeled as rising in the surrounding liquid because of buoyancy forces and even leaving the liquid if it reaches a free surface.
A front gear housing, 380 die cast alloy. Results are colored by percent of entrained air. Image courtesy of Albany-Chicago Co.
A support arm cast in A380. Result is colored by air entrainment. The major concern with the part was filling the deep and thin ribs. Image courtesy of Littler Diecast Co.
High Pressure Die Casting Hot Chamber Runner and Gate Design to Reduce Air Entrapment
Four different simulation cases of the Caster Wheel Leg part were run. These parts are made of Zinc alloy #5. Three cases 1-3 had different runners and all four cases had different sized overflows at different locations. Case 4 showed the best gating and overflow design to eliminate air entrapment. Casting simulation results courtesy of Deco Products. Simulation post-processed with FlowSight, coming soon in FLOW-3D v11.