Shahzadeh M, Teichmann F, Müller S (2026)
Publication Language: English
Publication Status: Published
Publication Type: Unpublished / Preprint
Future Publication Type: Journal article
Publication year: 2026
URI: https://arxiv.org/abs/2601.05701
DOI: 10.48550/arXiv.2601.05701
Air entrapment during mold filling critically affects porosity and
overall casting quality in High Pressure Die Casting. This study
assesses the feasibility of applying the vof method within OpenFOAM to
simulate compressible, turbulent mold filling in a thin-walled geometry.
Three-dimensional simulations with the "compressibleInterFoam" solver
were carried out under ambient initial cavity conditions, using both
laminar flow and the k-e turbulence model. The free surface dynamics
were examined across a range of inlet velocities to evaluate their
influence on interface morphology, cavity pressurization, and gas
entrapment. To quantify these effects, three evaluation criteria were
introduced: the TIFSA as a measure of oxidation risk, the TMVF as an
indicator of filling continuity and air entrapment, and the TIVF as a
proxy for surface loading. Results show that turbulence modeling
accelerates pressurization and limits the persistence of entrapped gas,
with velocity governing the balance between smooth filling, turbulent
breakup, and exposure duration. Comparison with experimental casting
trials, including CT based porosity analysis and photogrammetric surface
evaluation, validated that the model captures key defect mechanisms and
provides quantitative guidance for process optimization.
APA:
Shahzadeh, M., Teichmann, F., & Müller, S. (2026). Development and Experimental Validation of Novel Evaluation Criteria for Turbulent Two-Phase VOF Simulations in High-Pressure Die Casting. (Unpublished, Published).
MLA:
Shahzadeh, Mehran, Fabian Teichmann, and Sebastian Müller. Development and Experimental Validation of Novel Evaluation Criteria for Turbulent Two-Phase VOF Simulations in High-Pressure Die Casting. Unpublished, Published. 2026.
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