An experimental investigation of the filling of a thin section casting and simulation by the finite element method

A thin section filling model is summarized which adopts a finite element solution to the governing equations. This is compared with three experimental case studies. Two experimental case studies were established in this work, one based on flow visualization and the second on an experiment that uses a short shot method to build an image of the metal how pattern into a pressure die cast part. This shows how a jet forms at the gate early in the filling stage and that filling is completed in a zone opposite this gate section. When the numerical model was compared with experimental data gathered from a gravity sand casting and a simple semicylindrical section, very good agreement was displayed when a turbulent flow model was adopted. This model was also compared with results from the pressure die cast part, but with less success since at this stage of development it is not capable of capturing the hydraulic losses that are associated with sharp changes in section and flow direction.