Title: Mesh resolution consideration for the viability prediction of lost salt cores in the high pressure die casting process

Authors: B. Fuchs; C. Körner

Addresses: AUDI AG, I/PI-22, High Pressure Die Casting Parts, 85045 Ingolstadt, Germany ' Institute of Materials Science and Technology of Metals, University of Erlangen-Nuremberg, Martensstr. 5, 91058 Erlangen, Germany

Abstract: High pressure die casting is limited in its geometry since a lost core technology as with sand or low pressure casting is not state-of-the art. Using lost cores made from sodium chloride may be a solution for high pressure die casting. Due to the high dynamical forces during the casting process, core failure is still a problem, especially for high ingate velocities. In this contribution the possibilities of numerical simulation are investigated to predict core failure during the casting process. Numerical results are created with different mesh resolutions and compared to evaluate the simulation results with according mechanical characterisation. In this way an objective approach to find process parameters based on the mechanical properties of the salt cores without costly and time consuming trial-and-error-testing could be established. Furthermore, a critical mesh resolution could be determined.

Keywords: high pressure die casting; HPDC; lost cores; salt cores; undercuts; hollow parts; numerical simulation; fluid structure interaction; FSI; finite difference method; FDM; core failure; critical mesh resolution.

DOI: 10.1504/PCFD.2014.059197

Progress in Computational Fluid Dynamics, An International Journal, 2014 Vol.14 No.1, pp.24 - 30

Received: 08 May 2021
Accepted: 12 May 2021

Published online: 07 Feb 2014 *

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