LPDC Flow Simulation

CHINA FOUNDRY
Vol.6 No.1
Numerical simulation of low pressure

die-casting aluminum wheel
*Mi Guofa1, Liu Xiangyu2, Wang Kuangfei1, Fu Hengzhi1
(1. School of Materials Science and Engineering, Henan Polytechnic University, Jiaozuo 454003, P. R. China; 2. Department of Mechanical
Engineering, Chengde Petroleum College, Chengde 067000, P. R. China)
Abstract: The FDM numerical simulation software, ViewCast system, was employed to simulate the low
pressure die casting (LPDC) of an aluminum wheel. By analyzing the mold-lling and solidication stage of the
LPDC process, the distribution of liquid fraction, temperature field and solidification pattern of castings were
studied. The potential shrinkage defects were predicted to be formed at the rim/spoke junctions, which is in
consistence with the X-ray detection result. The distribution pattern of the defects has also been studied. A solution
towards reducing such defects has been presented. The cooling capacity of the mold was improved by installing
water pipes both in the side mold and the top mold. Analysis on the shrinkage defects under forced cooling mode
proved that adding the cooling system in the mold is an effective method for reduction of shrinkage defects.
Key words: numerical simulation; aluminum wheel; low pressure die casting; defect reduction; forced cooling
CLC number: TG146.2+1/TP391.9
Document code: A
Article ID: 1672-6421(2009)01-048-05
he automotive industry is moving towards expanding

the application of light-weight aluminum alloy castings
for various components that previously made from steels or
cast irons, for example, more than 50% of new cars in North
America are now equipped with aluminum alloy wheels [1].
Unfortunately, because of the multiple stringent requirements
for surface finish, impact and fatigue performance, air
tightness, geometric and rotational balance tolerances,
aluminum alloy die-cast wheels are one of the most difcult
castings to make in automotive and the rejection rates are often
high compared with other aluminum castings [2].
Low-pressure die casting (LPDC) process is a near net shape
casting method [3]. Due to the high precision and high efciency
requirements as well as its capacity for high quality wheels
at low cost LPDC is considered as the dominant process for
the production of aluminum alloy wheels. LPDC is a cyclic
process, which begins with the pressurization of the furnace.
The high pressure inside the furnace forces the aluminum
melt to rise up and enter the die cavity where it solidifies
by transferring the heat from the metal to the die. In LPDC
process the melt is poured from the bottom of the mould,
thus the mould-lling course is smooth and can be regulated
easily. Meanwhile, castings are solidified under external
*Mi Guofa
Male, born in 1966, professor, Ph.D, graduated from the Harbin
Institute of Technology (HIT) in 1989 and majored in Foundry,
and he got his masters degree and doctors degree from HIT in
1992 and 1995, respectively. His research interests are mainly
focus on metal solidication technology and new materials.
E-mail: [email protected]
Received: 2008-06-26; Accepted: 2008-08-13

48
pressure, leading to compact components with roughly 10%

improvement in their mechanical properties compared with
those manufactured by conventional foundry techniques [4-8].
To reduce the cost, it is necessary to identify the hard-tocast wheels prior to the die manufacture and prototyping, so
that castability issues can be explored early in the designing
stage to avoid the manufacture of faulty and expensive dies.
To take such advantages, the die casting industry has now
adopted the computer based simulation technique which
showed advantages over the conventional trial-and-error
methodologies for design and optimization [9-13]. In this paper,
the numerical simulation system ViewCast was used to
simulate the temperature and velocity elds during the lling
and solidication stages of LPDC aluminum alloy wheel. The
present work was aimed to predict the location and volume
of defects, and modication has been applied to the original
process in order to improve the quality of casting.
1 Experiment
1.1 Mathematical model
The flow of liquid metal was assumed to be incompressible
Newtonian fluid and the governing equations at the LPDC
lling and solidication stages are as follows:
Navier-stokes equation
(1)
(2)
(3)
Research & Development
February 2009
Table 1 Material properties of A356
Continuity equation
(4)
Material properties
Density
Heat-transfer equation
(5)
Where t is the density; u, v and w, the velocity vectors; t, the
time; , the dynamic viscosity of the liquid metal; gx, gy and
gz, the gravitational acceleration vectors; p, the pressure; Cp,
the specic heat of molten metal; m, the thermal conductivity;
T, the temperature; L, the latent heat and fs, the solid phase
fraction at the solidication stage.
Values
2.48510-3 (g/mm3, for solid)
2.41510-3 (g/mm3, for liquid)
Viscosity
2.9610-3 (g/(mm s))
Specic heat
0.963 (J/(g ))
Thermal conductivity
0.151 (W/(mm ))
Latent heat
389 (J/g)
Liquidus temp.
615
Solidus temp.
555
Gravity
9,800 (mm/ s2)
Table 2 Material properties of H13 steel
1.2 Geometric model

Figure 1 shows the geometric model of aluminum alloy
wheel, which was imported into the ViewCast. It consists of
10,000,000 FDM meshes, as shown in Fig. 2. The step length
of mesh generation was self-adjusting to ensure the thinnest
part of the casting can be divided into three meshes and ensure
the accuracy of ow simulation.
Material properties
Values
Density
7.810-3 (g/mm3)
Specic heat
0.422 (J/(g ))
Thermal conductivity
0.0287 (W/(mm ))
pressure of uid at the ingate; Vv is velocity of uid surface in

the crucible; Pv is the vapor pressure above uid; and h is the
height of ingate above the reservoir.
If we assume that the fluid velocity is relatively low (i.e.
the dynamic pressure is negligible) and that the volume of the
metal reservoir is substantially larger than the volume of the
casting (i.e. the height of fluid is constant), then the ingate
pressure can be expressed as a function of the applied air
pressure minus the hydrostatic head of molten metal.
(7)
Although we have assumed that the height of the fluid is
constant during the lling of each casting, this is not true from
one casting to the next. As molten metal is consumed, the
volume of fluid in the crucible will be reduced progressively
and the ingate height will increase. Therefore, in theory, the
ingate height should be measured before every simulation, but
in practice, it is not necessary because the uid is driven by the
increase rate of the applied pressure, rather than the absolute
pressure. Since the rate of increase is constant during the lling
process of the casting, the height of the riser-tube is irrelevant.
Based on the above analysis, the effect of molten metals
reduction in the crucible was neglected and the calculated
pressure at the gate, at a pouring temperature of 700 and a
mold temperature of 300, is listed in Fig. 3.
Fig. 1 3D model of aluminum alloy wheel
Fig. 2 The mesh of aluminum alloy wheel
1.3 Initial and boundary conditions

The wheel was cast from Sr-modied A356 (Al-7%Si-0.3%Mg)
alloy and the mold material was H13 steel. The properties
of the alloy and mold were listed in Table 1 and Table 2,
respectively.
The pressure boundary condition can only be used if the
pressure at the gate is known. The pressure applied on the
liquid surface in the crucible was known in advance and the
pressure at the ingate can be calculated with the Bernoulli
equation
(6)
Where Vi is the velocity of uid at the ingate; Pi refers to the
Fig. 3 The LPDC pressure curve
49
CHINA FOUNDRY
Vol.6 No.1
2 Simulation results and discussion

The mold-filling analysis was conducted on an aluminum
wheel produced by the LPDC process, and the simulation
results are shown in Fig. 4. It indicates the positions of the

molten aluminum front in the cavity at different lling time.
The whole lling process takes 16.9 s.
Fig. 4 Temperature distribution during mold-lling stage
At 1.1 s, the molten metal flows through the running

system into the die cavity and then lls the centre of the hub.
At 2.5 s, the front reaches the junctions between the rim
and the spokes, and lls the bottom of the rim at 4 s. At this
moment, the temperature of the alloy is about 600. The
liquid metal reaches the middle of the rim at 13.34 s with a
temperature of about 590, and reaches the top of the rim at
16.9 s. Figure 4 shows that the lling behavior is stable and
propitious to prevent the formation of gas entrapment during
the lling stage. When the cavity is lled entirely, no misrun
and cold-shut are found at the top of the rim. At this time, the
temperature of the front metal is about 580, which is in the
semisolid state. In order to measure the temperature difference
between the top and the bottom of the rim, three monitors were
xed at the middle of the rim, at the rim/spoke junction and
at the top of the rim, respectively, as shown in Fig. 5. Figure
6 reveals the temperature evolution during the lling stage at
these positions.
Fig. 5 Positions of monitors
50
Fig. 6 Temperature curves of the monitored points

during lling
Once the mold cavity is completely filled, solidification

simulation is followed. The lling simulation results should be
used as the initial temperature distribution of the solidication
simulation for accuracy. Solidication is completed at 192 s.
Figure 7 shows the solidication time at critical regions.
Figures 7(f) and (g) shown that solidication at the spokes,
which begins at 53 s and nishes at 59 s, is faster than that
at other positions. As a result, some isolated liquid regions
(liquid islands) form at the rim/spoke junctions and eventually
leading to shrinkages, as shown in Fig. 8. Figure 9 is the result
of X-ray detection, exhibiting good agreement between the
simulation and the practical measurement, with high accuracy
for the predicted volume and position of the shrinkage.
During solidication stage, the temperature at the rim/spoke
junction is higher than that at the middle rim and top rim, as
shown in Fig. 10. Consequently, hot spots (liquid islands) at
the rim/spoke junctions result (Fig. 7g), leading to potential
shrinkages at the final stage of the solidification. Due to
Research & Development
February 2009
217
167
(a) 21 s
(b) 25 s
(c) 29 s
(d) 33 s
117
67.1
(a) 39 s
(b) 53 s
(c) 59 s
(d) 69 s
17.0
Fig. 7 Solidication time at critical regions
the above reasons, the entire solidification process is not a

directional solidication pattern from the rim top towards the
hub center.
3 Defects reduction
Fig. 8 The predicted shrinkage defects
Above analysis suggests that the hot spots occur at the rim/
spoke junctions. In order to prevent the formation of shrinkage
defects, the cooling capacity of the mold was enhanced by
adding cooling water pipes at both the top mold and the side
mold, as shown in Fig. 11. The diameter of the water pipe is
20 mm, and the temperature of the cooling water is 20.
1-Top mold 2-Side mold 3-Casting

4-Lower mold 5-Water pipes
Fig. 9 Result of X-ray detection
Fig. 10 Temperature curves of the monitored points

during solidication
Fig. 11 Sketch showing the location of cooling

water pipes
Figure 12 displays the solidification sequence of the

wheel under forced-cooling. It showed that the time for the
generation of liquid islands is about 44 s, which is brought
forward by about 15 s when compared with the result obtained
by using of the mold without forced-cooling. The liquid
islands disappeared about 18 s ahead of the original process.
In comparison of Fig. 7 with Fig. 12, it can be seen that the
volume of the liquid island was decreased, however their
locations remain unchanged. We shall study and optimize the
process to shift the liquid islands in the center of the wheel
in the future. Figure 13 shows the simulation result of defect
under forced-cooling.
51
CHINA FOUNDRY
Vol.6 No.1
178
138
(a) 16.91 s
(b) 18.52 s
(c) 20.13 s
(d) 23.36 s
97.5
57.2
(a) 26.58 s
(b) 37.87 s
(c) 44.32 s
(d) 51.12 s
16.9
According to the
above analysis, it seems
that defects that caused
by the structure of the
casting can be reduced
to a certain extent
but cannot be totally
eliminated. Defects are
hard to be eliminated
without structural
modification of the
casting. This is also
in line with the actual
results [14].
Fig. 12 Solidication time at critical regions under forced-cooling
[3]
[4]
[5]
Fig. 13 Predicted shrinkage defects under forced-cooling
4 Conclusions
Numerical simulation was applied to LPDC of aluminum
wheel. The lling and solidication stages were numerically
analyzed. Conclusions were drawn as the following:
(1) Study on positions of the molten front in the cavity at
different filling time has revealed that the filling behavior
of the LPDC process is stable, which is favorable for the
prevention of gas entrapment at the lling stage, hence, avoid
the formation of gas pores in the casting. The temperature
eld investigation indicate that the temperature distribution in
this stage is appropriate, and there is no misrun and cold-shut
formed at the top of the rim.
(2) The potential of forming shrinkage defects at the rim/
spoke junctions was predicted, and the predicted result agrees
well with the results obtained by X-ray detection analysis.
(3) Cooling water pipes in both of the side mold and the top
mold can reduce the hot spots at rim/spoke junctions. This led
to the decrease of the liquid island volume to a certain extent
and satises the practical requirement in production.
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
References
[1]
[2]
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Zhang B, Cockcroft S L, Maijer D M, et al. Casting defects
in low-pressure die-cast aluminum alloy wheels. JOM, 2005,
[14]
57(11): 36-43.
Bonollo F, Urban J, Bonatto B, et al. Gravity and Low pressure
die casting of aluminum alloys: A technical and economical
benchmark. Metallurgia Italiana, 2005, 97(6): 23-32.
Anon. Low pressure permanent mould casting of magnesium.
Recent developments. Foundry Trade Journal, 1989,
163(3399): 3-7.
Srinivasan A, Pillai U T S, John V, et al. Low-pressure casting
of LM25 (Al-7Si-0.3 Mg) aluminum alloy. Materials and
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Plume A W. Low-pressure die casting - A practical assessment.
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The present work is funded by the Innovation Fund for Outstanding Scholar of Henan Province (No.0621000700)
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CHINA FOUNDRY

Numerical simulation of low pressure

he automotive industry is moving towards expanding

Received: 2008-06-26; Accepted: 2008-08-13

pressure, leading to compact components with roughly 10%

Research & Development

Table 1 Material properties of A356

2.9610-3 (g/(mm s))

9,800 (mm/ s2)

Table 2 Material properties of H13 steel

1.2 Geometric model

pressure of uid at the ingate; Vv is velocity of uid surface in

Fig. 1 3D model of aluminum alloy wheel

Fig. 2 The mesh of aluminum alloy wheel

1.3 Initial and boundary conditions

Fig. 3 The LPDC pressure curve

2 Simulation results and discussion

results are shown in Fig. 4. It indicates the positions of the

Fig. 4 Temperature distribution during mold-lling stage

At 1.1 s, the molten metal flows through the running

Fig. 5 Positions of monitors

Fig. 6 Temperature curves of the monitored points

Once the mold cavity is completely filled, solidification

Research & Development

Fig. 7 Solidication time at critical regions

the above reasons, the entire solidification process is not a

Fig. 8 The predicted shrinkage defects

1-Top mold 2-Side mold 3-Casting

Fig. 10 Temperature curves of the monitored points

Fig. 11 Sketch showing the location of cooling

Figure 12 displays the solidification sequence of the

Fig. 12 Solidication time at critical regions under forced-cooling

Fig. 13 Predicted shrinkage defects under forced-cooling

Chiesa F. Influence of some processes and metallurgical

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