It was found that vent resistance and vent location strongly affected die filling time, free surface topography, and air entrainment for a given pressure fill-curve. The filling model was first validated against experimental data, and then was used to investigate the effects of venting conditions and pressure curves during die filling. To fully understand the behavior of the free surface, a novel technique was developed to approximate the vent resistances as they impact on the development of a backpressure within the die cavity. The filling model represents a 36-deg section of a production wheel, and was developed within the commercial finite-volume package, ANSYS CFX, assuming isothermal conditions. A two-phase computational fluid dynamics model of the low-pressure die-cast process for the production of A356 aluminum alloy wheels has been developed to predict the flow conditions during die filling.
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