HPDC Webinar Series: Part II – Filling

High pressure die casting (HPDC) simulations are typically quite complex. To accurately model the entire physical process one needs to account for heat transfer, melting and solidification, air entrainment, surface defect tracking and cavitation. In this three-part webinar series, we will simulate the entire HPDC process in FLOW-3D CAST. We will also demonstrate the power of the new process-oriented workspace that implements the necessary physical models and numerical defaults while setting up the stages of thermal die cycling, filling, solidification and cooling.

In the first part of our webinar series, we looked at the wall temperatures of the die under the combined effects of die heating, spray cooling, air blow-off and cooling channels.

Now that we have obtained the steady state thermal die profile from the thermal die cycling simulation, we will analyze the filling of the die. In the second part of our webinar series, we implement a properly designed shot sleeve profile to rapidly push metal into the die. In this stage of the simulation, the molten metal needs to quickly fill the die to prevent early solidification. At the same time, care should be taken so that the liquid metal front does not fold over itself causing air entrainment that results in internal defects or any potential surface defects formed by oxides. This is one of the more challenging simulations as it entails accurately tracking the metal front at high pressures and velocities.