FLUID FLOW AND SOLIDIFICATION MODELING OF DIE CASTINGS.

A two-stage model for fluid flow and solidification during the die casting process is presented. In the filling stage, the flow patterns are predicted using the volume of fluid approach. These predictions are compared with photographs of experiments using water for a variety of geometries including an obstacle within the die cavity and multiple gates. In the solidification analysis, a fixed grid enthalpy technique is used to model the phase change with convection and diffusion occurring after the cavity is filled with liquid aluminum. A feature of this model is the prediction of the shape of the solid-liquid interface. Emphasis is placed on the effect of residual velocities on this interface.