On determining lost core viability in high-pressure die casting using Computational Continuum Mechanics

개요:

  • 제목: On determining lost core viability in high-pressure die casting using Computational Continuum Mechanics
  • 저자: Sebastian Kohlstädt
  • 발행 연도: 2019
  • 발행 학술지/학회: Doctoral thesis, KTH Royal Institute of Technology
  • Keywords:
    • high-pressure die casting
    • lost salt cores
    • computational continuum mechanics
    • two-phase compressible flow
    • OpenFOAM
    • CFD
    • fluid-structure interaction
    • volume-of-fluid method

연구 배경:

  • 연구 주제의 사회적/학문적 맥락:
    • 고압 다이캐스팅은 자동차 및 관련 산업에서 중요한 공정입니다.
    • 로스트 코어 기술은 냉각 또는 오일 흐름을 위한 내부 형상을 생성하여 기능성을 향상시킬 수 있습니다.
  • 기존 연구의 한계점:
    • 2019년 봄 기준으로 고압 다이캐스팅에서 로스트 코어의 양산 적용 사례가 알려져 있지 않습니다.
    • 이는 공정 및 주조 개념의 타당성을 사전에 판단할 수 있는 엔지니어링 도구의 부재 때문이라고 여겨집니다.
  • 연구의 필요성:
    • 로스트 코어를 사용한 하우징 설계가 허용 가능한 불량률과 원하는 냉각 성능으로 제조 가능한지 여부를 사전에 결정하는 도구가 필요합니다.

연구 목적 및 연구 질문:

  • 연구 목적:
    • 전산 연속체 역학(CCM)이 주조 엔지니어가 로스트 코어를 사용한 하우징 개념의 타당성을 사전에 결정하는 데 유용한 도구 역할을 할 수 있는지 조사합니다.
  • 핵심 연구 질문:
    • OpenFOAM의 CCM 모델은 로스트 코어를 사용한 하우징 설계의 제조 가능성을 사전에 판단할 수 있는가?
  • 연구 가설:
    • OpenFOAM 툴박스 내의 CCM 모델은 로스트 코어를 사용한 하우징 설계의 제조 가능성을 사전에 결정할 수 있습니다.

연구 방법론

  • 연구 설계:
    • OpenFOAM 툴박스 내에 CCM 모델을 제시, 구현 및 테스트합니다.
  • 데이터 수집 방법:
    • 검증을 위해 고압 다이캐스팅 실험을 수행했습니다.
  • 분석 방법:
    • 공기 및 용융물의 2상 흐름은 VOF(Volume of Fluid) 개념으로 모델링되었습니다.
    • 난류 모델링은 RANS(Reynolds-Averaged-Navier-Stokes) 접근 방식을 통해 수행되었으며, 주로 Menter SST k-ω 모델을 사용했습니다.
    • 고체 역학에는 등방성 선형 탄성 모델이 가정되었습니다.
    • 실험 결과 및 기존 연구 결과와 비교 분석했습니다.
  • 연구 대상 및 범위:
    • 로스트 염 코어를 사용한 고압 다이캐스팅의 내부 형상을 가진 하우징 개념을 연구 대상으로 합니다.
    • 다이캐스팅 공정 중 다이캐스팅 충전 단계에 초점을 맞추었습니다.

주요 연구 결과:

  • 핵심 연구 결과:
    • CCM 모델은 각 설정을 개별적으로 테스트할 수 있습니다.
    • 로스트 코어로 제작된 하우징은 주조품의 열 전달 능력을 향상시킬 수 있습니다.
    • 최대 30 ms⁻¹의 충격 속도에서 코어를 사용하여 주조품을 생산할 수 있었습니다.
    • 충격 속도가 가장 결정적인 매개변수임을 확인했습니다.
    • 균열 없는 코어를 사용하면 용융물의 첫 번째 충격 시 슬래밍 이벤트가 파손에 결정적이지 않다는 것을 발견했습니다.
    • 피크 힘만 평가하는 접근 방식은 충분하지 않다는 것을 발견했습니다.
    • 충전 시간이 0.1초 미만이라도 용융물에서 코어로 전달되는 열을 무시할 수 없습니다.
  • 통계적/정성적 분석 결과:
    • 실험 및 기존 연구 결과와 비교했을 때 최대 5-10%의 편차를 보였습니다.
    • 정확한 슬래밍 계수를 얻기 위해서는 0.3mm 이하의 메쉬 세분화가 필요합니다.
    • 난류 모델 선택은 결과에 미미한 영향을 미칩니다.
  • 데이터 해석:
    • CCM 모델은 주조 또는 CAD 엔지니어가 주조 개념의 생산 가능성을 사례별로 결정하는 데 강력한 도구를 제공할 수 있습니다.
    • 도구는 제한된 CFD 접근 방식부터 완전 결합된 FSI 방법론까지 다양합니다.
  • Figure Name List:
    • Figure 1: The layout and components of a high-pressure die casting machine according to DIN 24480
    • Figure 2: Process steps during high-pressure die casting (HPDC)
    • Figure 3: Conceivable applications of lost core technology for creating inlying channels in cast housings in the automotive industry
    • Figure 4: Illustration of the volume-of-fluid method of distinguishing between the phases via an indicator function assigning a value between 0 and 1 to each cell
    • Figure 5: Solving process scheme of fsiFoam Solver
    • Figure 6: PISO algorithm before and after the adjustments
    • Figure 7: Mechanism of transferring the field data at the fluid-solid interface
    • Figure 8: The tool concept for validation of the simulations in high-pressure die casting experiments. There is always a pair of inserts for the moving side (ms) and the fixed side (fs); (a) is the setup for the straight ingate, (b) represents the tooling parts for the fork ingate
    • Figure 9: An engineering drawing of the salt core geometry of the ultimately selected shape: a rectangular cross-section with 10 mm in width and 3, 5 and 7 mm in thickness.
    • Figure 10: The geometry for investigating the slamming on a salt core in a channel; all dimensions in mm
    • Figure 11: Mesh study of the slamming factor in comparison with models by von Karman [118] and Wagner [121]
    • Figure 12: Comparison of the computed result with reference studies in previously published articles
    • Figure 13: Influence of the selected turbulence model on the computed result of the slamming factor
    • Figure 14: Different strategies for calculating the turbulence in the Navier-Stokes equations
    • Figure 15: The flow pattern on the 2D-mesh at three different time steps, illustrating the influence of the selected turbulence model on the morphology of the melt-air interface: (a) k-ɛ; (b) k-w-SST; (c) Spalart-Allmaras. Red areas characterise the melt, blue areas the air and the mixed colours (white/orange) regions are the interface between melt and air
    • Figure 16: Comparison of the effective mean pressure force in the x-direction when using different turbulence models; the vertical bars show the standard deviation
    • Figure 17: Comparison of the necessary computational time in minutes when doing the simulations with the particular turbulence model
    • Figure 18: Benchmarking of the presented OpenFOAM model with previously published data by Korti and Aboudi [71]; the figure shows the interface positions at various time steps
    • Figure 19: The fraction occupied by air after the melt-front has propagated into the ingate; the numerical values represent the different piston velocities in ms-1
    • Figure 20: The deformation of the salt core in a casting experiment; Uin = 30 ms-1
    • Figure 21: The deformation of a cracked salt core in a casting experiment; Uin = 50 ms-1
    • Figure 22: The deformation of the salt core after 0.016 s, as predicted by the CFD simulation; Uin = 30 ms-1
    • Figure 23: The filling pattern of the melt and core displacement at a fill fraction of 95 %; Uin = 30 ms-1
    • Figure 24: The displacement of the salt core centre in the x-direction over time
    • Figure 25: Sketch of the simplified simulation; note that the entire domain is filled with melt as this is a single-phase flow model
    • Figure 26: Result of the mesh independency study
    • Figure 27: Temperature in salt core at times t=(0.1s, 0.5s, 1s, 1.5s, 2s) from left to right
    • Figure 28: Spatial temperature distribution in x-direction through the middle of the core
    • Figure 29: Dimensionless temperature distribution through the salt core at time t=1 s
    • Figure 30: Dimensionless temperature distribution through the salt core at time t=2 s
    • Figure 31: A strategy proposal for designing castings with lost cores and the corresponding manufacturing process
    • Figure 32: The impossible triangle of computational continuum mechanics in high-pressure die casting

결론 및 논의:

  • 주요 결과 요약:
    • CCM은 로스트 코어를 사용한 고품질 주조품 설계를 위한 강력한 도구입니다.
    • 완전 통합 모델보다 분리된 접근 방식이 더 유용합니다.
    • 잉게이트 속도, 코어 직경 및 다이 단면이 주요 결정 요인입니다.
    • 코어로의 열 전달이 중요합니다.
  • 연구의 학술적 의의:
    • HPDC에서 로스트 코어의 타당성을 위한 검증된 CCM 모델을 제시했습니다.
    • FSI 및 열 전달의 중요성을 입증했습니다.
  • 실무적 시사점:
    • 로스트 코어를 사용한 주조품 설계를 위한 엔지니어링 전략을 제공했습니다.
    • CCM은 타당성을 평가하고 공정을 최적화하는 데 도움이 될 수 있습니다.
  • 연구의 한계점:
    • 모델의 가역성, FSI 모델의 소성 변형 및 열 전달 부족, 산업 형상에 대한 안정성 문제, 솔루션 시간 등이 있습니다.

향후 후속 연구:

  • 후속 연구 방향:
    • CCM 모델 안정성 개선, 염 코어용 고체 모델 확장(소성, 파괴), FSI 모델에 열 전달 포함, 염 코어 생산 기술 발전, 슬래밍 힘 실험적으로 측정, 산업 형상에 적용.
  • 추가 탐구가 필요한 영역:
    • 소성 변형, 코어 강도에 대한 열 전달 효과, 샷 슬리브 매개변수 최적화, CCM의 견고하고 효율적인 산업적 적용.

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