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TECHNICAL PAPERS

On the Critical Plunger Speed and Three-Dimensional Effects in High-Pressure Die Casting Injection Chambers

[+] Author and Article Information
J. López, F. Faura

Dept. de Ingenierı́a de Materiales y Fabricación, ETSII, Universidad Politécnica de Cartagena, E-30202 Cartagena, Spain.

J. Hernández, P. Gómez

Dept. de Mecánica, ETSII, UNED, E-28040 Madrid, Spain.e-mail: pgomez@ind.uned.es

J. Manuf. Sci. Eng 125(3), 529-537 (Jul 23, 2003) (9 pages) doi:10.1115/1.1580525 History: Received January 01, 2002; Revised December 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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References

Figures

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Grid sensitivity of results for wave surface profiles at different instants. Case with the plunger acceleration law of Eq. (7) with c0=(gh0)1/2,Al0/A=0.2,L/l=1,L/H=9 and H=5.08 cm. (a) Wave profiles in the symmetry plane of the injection chamber; (b) Free surface profiles at the plunger face.
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Wave surface profiles in an injection chamber of circular cross section and length L=9H, for initial filling fractions Al0/A=0.2, 0.374 and 0.5, and the plunger acceleration law of Eq. (6). Equation (14) is satisfied, with c0=(gHAl0/A)1/2 in Eq. (15).
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Wave surface profiles in an injection chamber of circular cross section and length L=9H, for initial filling fractions Al0/A=0.2, 0.374 and 0.5, and the plunger acceleration law of Eq. (7), with l=L and c0=(gHAl0/A)1/2
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Comparison between the values predicted by the shallow-water and CFD models for the plunger speed required for the molten metal to reach the chamber ceiling, UH, and the maximum speed, Umax, that, according to the CFD model, the plunger can reach without causing the formation of wall jets along the ceiling. (a) Plunger acceleration law of Eq. (6); (b) Plunger acceleration law of Eq. (7).
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Comparison between wave surface profiles in the symmetry plane of a chamber with a circular cross section obtained from the CFD and shallow-water models, and the analytical profiles predicted by the shallow-water model in an equivalent two-dimensional chamber configuration, for different initial filling fractions and the plunger acceleration law of Eq. (7) with L/l=1
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Influence of the maximum velocity reached by the plunger on the free-surface profile near the chamber ceiling, for the plunger acceleration law of Eq. (7), with l=L and c0=(gAl0/T0)1/2, in a chamber with L/H=9. a) Al0/A=0.2; b) Al0/A=0.5
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Schematic representation of the computational mesh in the injection chamber
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Schematic representation of the problem and coordinate system. Symmetry plane (left) and cross section (right) of the chamber.
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Sketch of a horizontal cold chamber die casting machine (a) slow shot stage (b) fast shot stage

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