Numerically modeling oxide entrainment in the filling of castings: The effect of the webber number

Cuesta, Rafael; Delgado, A.V.; Maroto, A.; Mozo, David

doi:10.1007/s11837-006-0229-z

Cited by 7 publications

(4 citation statements)

References 1 publication

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“…The limiting velocity depends on material and geometry parameters and ensures a controlled filling and avoids air entrainment. For aluminum alloys, the critical velocity ranges from 0.3 m/s to 0.5 m/s for a channel thickness between 3 mm and 25 mm [17].…”

Section: Process Simulationmentioning

confidence: 99%

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

et al. 2021

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The structural optimization of manufacturable casting parts is still a challenging and time-consuming task. Today, topology optimization is followed by a manual reconstruction of the design proposal and a process assurance simulation to endorse the design proposal. Consequently, this process is iteratively repeated until it reaches a satisfying compromise. This article shows a method to combine structural optimization and process assurance results to generate automatically structure- and process-optimized die casting parts using implicit geometry modeling. Therefore, evaluation criteria are developed to evaluate the current design proposal and qualitatively measure the improvement of manufacturability between two iterations. For testing the proposed method, we use a cantilever beam as an example of proof. The combined iterative method is compared to manual designed parts and a direct optimization approach and evaluated for mechanical performance and manufacturability. The combination of topology optimization (TO) and process assurance (PA) results is automated and shows a significant enhancement to the manual reconstruction of the design proposals. Further, the improvement of manufacturability is better or equivalent to previous work in the field while using less computational effort, which emphasizes the need for suitable metamodels to significantly reduce the effort for process assurance and enable much shorter iteration times.

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Section: Process Simulationmentioning

confidence: 99%

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

et al. 2021

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“…However, filling velocity was not the only oxide entrainment criterion ever considered. Kuo et al proposed to consider the Reynolds number as an oxide entrainment criterion instead [4], while Cuesta et al proposed to consider the Weber number [5]. Indeed, analyzing fluid flow simulation of different alloys and channels geometries, they highlighted the additional influence of the channel geometry in the flow structure.…”

Section: Introductionmentioning

confidence: 99%

Geometrical effects on filling dynamics in low pressure casting of light alloys

Bedel

Sanitas

Mansori

2019

Journal of Manufacturing Processes

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In aluminum low-pressure sand casting process, filling oscillations are observed when the metal front reaches a section change in a part. The effect of geometry on the filling oscillations is primary considered experimentally, including both mold cavity and filling system geometries. To highlight the geometric parameters impacting the oscillations, the pressurized melt flow is secondly studied numerically and analytically. A new analytical model of oscillation is developed to quantitatively predict the oscillations. It links the resulting filling velocity to both the low-pressure casting parameters and the mold cavity geometry. Considering oxides inclusion criterion from casting literature, new rules to avoid bi-films defects are recommended for making reliable low-pressure castings.

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“…Cuesta et al have found that the amount of oxide entrained into the liquid is related to the We number[75]. Reilly et al have used the calculated Froude number entrainment criterion to assess the overall quality of the running system, and their predictive results correlated well against quantitative data (Weibul moduli) obtained by experiments assessing three different running systems[54].…”

mentioning

confidence: 99%

Physical and Computational Models of Free Surface Related Defects in Low‐Pressure Die‐Cast Aluminum Alloy Wheels

et al. 2011

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The difference of die filling, which can be characterized by the free surface flow behavior, has a strong influence on the quality of casting components. In the case of cast aluminum alloy wheels, an undesired filling pattern with excessive turbulence can cause portions of the surface oxide film to be entrained within the bulk liquid resulting in defects such as cosmetic paint-pops, hot tears, porosity and rim-leaks.To investigate the influence of die filling on defect formation in low-pressure die-cast aluminum wheels, a water analogue physical model was built, instrumented and tested to simulate the free surface behavior during die filling of a low-pressure die-cast (LPDC) wheel. The physical model contains a transparent planar die section which was manufactured out of the geometry of a production die, and an automatic pressure control system that achieves liquid feeding conditions similar to the industrial process. A set of die filling tests with different venting conditions was carried out to explore the role of venting on the free surface behavior of water and to produce data for validation of a computational model. The computational model was developed, based on the commercial computational fluid dynamics code ANSYS CFX, for the purposes of predicting the flow conditions during die filling, providing qualitative a nd quantitative flow information that are otherwise not possible to obtain through experimental measurement, and identifying key features that influences the flow during die filling at a lower cost of time and labor.Comparison between the experimental and numerical data has shown that the computational model was able to qualitatively reproduce the flow behavior observed in the water model in the conditions tested. Both the experimental and the model results indicate that the entrainment of surface oxide films and air bubbles could occur at the outboard rim flange during the filling of the flange, below the free surface of the returning waves in the spoke and at the junction of the iii hub and the spoke during the filling of the hub. In both cases, venting conditions have been proved crucial and the importance of vent design in commercial die design was highlighted.iv

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Numerically modeling oxide entrainment in the filling of castings: The effect of the webber number

Cited by 7 publications

References 1 publication

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

Geometrical effects on filling dynamics in low pressure casting of light alloys

Physical and Computational Models of Free Surface Related Defects in Low‐Pressure Die‐Cast Aluminum Alloy Wheels

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