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Casting2 Access RL PDF
Casting2 Access RL PDF
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STAR-Cast
Common Materials:
Aluminum alloys
Magnesium alloys
Zinc alloys
Copper alloys
HPDC process cycle, horizontal cold chamber machine
Thin walled, complicated and large castings challenging enmeshment and high cell count
Multi physics: melt, solid, gas VoF model with HRIC scheme, combined with surface
tension model and correct wetting angle
Short pouring times, leading to high fluid velocities small time steps (~0.1ms) mandatory
Extreme pressure ranges from 10 Pa initial cavity pressure up to 1000 bar in melt during
solidification Compressibility model for melt and gas
Why simulate?
Features
Filling Simulation
Gas is Compressible
Liquid is Compressible
Moving Mesh
Phase Change
Conjugate Heat Transfer
Simulation
Shot chamber is half filled with liquid,
plunger follows shot control curve, pushing
the fluid into the cavity
High Pressure Die Casting: shot curve vPlunger=f(t)
Cast
Die parts
Meshing
Enter values or
read from file
Process parameter setup
Enter values or
read from file
Die cycle warm up simulation
Final temperature
distribution in die is used as
initial state for main
simulation run with coupled
filling and solidification
Initial temperatures in die and shot sleeve
Pressure on
melt surface
Velocity on
melt surface
Temperature distribution on melt surface during mold filling