Mold Filling Research Articles

Direct Observation and Numerical Simulation of Mold Filling during Vacuum Suction Casting

Direct Observation and Numerical Simulation of Mold Filling during Vacuum Suction Casting

Mold Filling Simulation Method Using Non-Orthogonal Element by the Direct Finite Difference Method

Mold Filling Simulation Method Using Non-Orthogonal Element by the Direct Finite Difference Method

Simulation of Oxides Entrapment during Mold Filling of Al-Alloy Casings

Simulation of Oxides Entrapment during Mold Filling of Al-Alloy Casings

Effect of Gate Thickness on Mold Filling Behavior in Aluminum Alloy Die Casting

Effect of Gate Thickness on Mold Filling Behavior in Aluminum Alloy Die Casting

Three Dimensional Computer Simulation of Mold Filling of Casting by Direct Finite Difference Method

Three Dimensional Computer Simulation of Mold Filling of Casting by Direct Finite Difference Method

Comparison between Numerical Simulation and Direct Observation of Mold Filling Behavior of Tire Mold Casting

Comparison between Numerical Simulation and Direct Observation of Mold Filling Behavior of Tire Mold Casting

Transferred Pressure Transfer Relationship between Mold Filling Flow of Multi-Piece Aluminum Die Cast

Transferred Pressure Transfer Relationship between Mold Filling Flow of Multi-Piece Aluminum Die Cast

Two Dimensional Computer Simulation of Mold Filling by Using Orthogonal-Nonorthogonal-Mixed Elements

Two Dimensional Computer Simulation of Mold Filling by Using Orthogonal-Nonorthogonal-Mixed Elements

Improvement in Calculation Stability and Velocity Decay Behavior of Mold Filling Simulation Using MPS Method

Improvement in Calculation Stability and Velocity Decay Behavior of Mold Filling Simulation Using MPS Method

Modeling and Simulation of Fiber Reinforced Polymer Mold Filling Process by Level Set Method

Modeling and Simulation of Fiber Reinforced Polymer Mold Filling Process by Level Set Method

Three-Dimensional Modelling to Study the Effect of Die-Stacking Shape on Mould Filling During Encapsulation of Microelectronic Chips

Multistacked-chip scale package (S-CSP) is a new technology that provides high density electronic package. A fully 3-D numerical model is developed to simulate mould filling behavior in the epoxy moulding compound (EMC) encapsulation of multi-S-CSP. Four different shapes of chip arrangement namely uniform, rotated, z-staggered-Type A and z-staggered-Type B, have been tested. The EMC is treated as a generalized Newtonian fluid (GNF). The developed methodology combines the Kawamura and Kuwahara technique-based finite difference method (FDM) and the robustness of volume-tracking (VOF) method to solve the two-phase flow field around the complex arrangement of microchips in a cavity. The Castro-Macosko rheology model with Arrhenius temperature dependence is adopted in the viscosity model. Short-shot experiments are conducted to investigate the filling patterns at several time intervals. The results show that the rotated shape die-arrangement gives minimum filling time and better mould filling yield. The close agreement between the experimental and simulation results illustrates the applicability of the proposed numerical model.

Research on Mould Filling and Solidification of Titanium Alloy in Vertical Centrifugal Casting

Abstract The objective of this paper is to study the filling process of titanium alloy melt in vertical centrifugal casting, as well as the effect of processing parameters on the formation of defects of titanium alloy castings. Experimental results show that the castings obtained in the centrifugal field are better than that obtained in the gravity field. The molten metal sticks to one side of the mould which is opposite to the rotational direction to fill in the vertical centrifugal field. And the cross-sectional area of the molten metal in the runner decreases with increasing of filling length, but has a back-up trend at the inlet of ingate due to the decreases of filling velocity at the ingate. The processing parameters such as rotational direction, rotational radius and rotational velocity play an important role in the formation of defects of titanium alloy castings. Different rotational direction leads to different filling sequence of molten metal, which then affect the following solidification and the formation of the defects. Under the given rotational velocity, the volume of inner defects of castings decreases with increasing of rotational radius and rotational velocity.

711 Megasonically Mold Filling for Replication of Complex Microstructures

711 Megasonically Mold Filling for Replication of Complex Microstructures

In situ Studies and Simulations of Mould Filling with a Model System for PIM

Abstract The processing conditions and the mould design are important parts of the powder injection moulding (PIM) process. In the present work, the mould filling phase of the process has been studied in situ with a special mould equipped with a sight glass using a high speed camera. Effects of features such as the mould temperature, the melt temperature, the surface roughness of the mould cavity, the gate dimensions, the mould design and the flow rate on the filling behaviour were demonstrated. In particular it was noted that a rougher mould surface to some extent facilitated the filling of the mould. The mould temperature, the nominal melt temperature and the flow rate affected the position of weld lines via the cooling of the feedstock and the corresponding change of the melt viscosity. The experimentally determined weld-line positions were compared with predictions from numerical simulations performed with the commercial software Moldex3D. The agreement between the experiment and the prediction was in most cases quite fair or good. The in situ observation of the mould filling also provided the possibility to study how the gate dimensions and the flow rate influenced the jetting behaviour.

Study on Mold Filling Behaviors of Micro Channels in Injection Molding

Abstract Computational simulation model has been used extensively in studying the filling flow in injection molding process. Most of the models are based on the assumption of a no-slip boundary condition and are verified by the experiments of filing flow in macro scale. This study is to investigate the flow behaviors during the micro channel filling of an injection molding process. Flow distances were measured on products from series of short shots to understand the relationship between the injection pressure and flow distance. It was found that cavity size variation due to mold deformation is important in the micro injection molding. By adjusting the cavity size due to mold deformation, the C-Mold simulation provides reasonable results compared to the experimental data for cavity thickness in 150 μm or 200 μm. On the other hand, the simulation will not give accurate prediction of filling flow for a micro cavity that has a depth below 100 μm. The wall slip effect is believed to the major reason and must be considered in the analysis for a cavity size below 100 μm.

Numerical Simulation of Mold Filling Processes with Polyurethane Foams

AbstractDesign and dimensioning of manufacturing processes based on filling molds with polyurethane foams still require the use of highly empirical approaches. This includes numerous experimental runs with expensive prototypes. Therefore, a method has to be found to analyze the molding process at an early stage of product development to shorten time‐to‐market cycles and cut costs by using fewer prototypes. With the computational power available today and growing computational power in the future, the tool of choice is the numerical simulation of mold filling processes with computational fluid dynamics software.

Effect of Carbon Nanofibers on Mold Filling in a Vacuum Assisted Resin Transfer Molding System

In this article, a new manufacturing method was used to prepare the hybrid composite, wherein carbon nanofibers were sprayed and bonded onto continuous fiber mats instead of pre-mixing them in the polymer resin. The effect of carbon nanofibers on the mold filling characteristics in a vacuum assisted resin transfer molding system was investigated. A simple one-dimensional flow model was used to correlate the permeability and porosity to the mold filling time. It was found that the dispersion and loading of the carbon nanofibers affected the permeability and porosity of the reinforcement system, and hence the mold filling time.

Accuracy Improvement of Mold Filling Simulation of Die Casting by Porous Media Method

Accuracy Improvement of Mold Filling Simulation of Die Casting by Porous Media Method

Simple Model on Mold Filling of Molten Aluminum Alloy in Expandable Pattern Casting Process

Simple Model on Mold Filling of Molten Aluminum Alloy in Expandable Pattern Casting Process

Application of Internal Variable Convection for Modelling of T-Shape Mould Filling

Numerical methods for thixoforming modelling are shortly reviewed in the paper. Present applications, especially for thixotropy phenomena modelling, are presented. Advantages and disadvantages of methods based on solid mechanics or computational fluid dynamics are pointed out. Internal Variable Convection (IVC) method is introduced as an alternative for classical Lagrangian or Eulerian methods. Numerical simulations of T-shape mould filling, based on the data taken from literature, are shown. Presented results confirm possibilities of thixoforming processes modelling with Internal Variable Convection method. However, some deficiencies of the present solution are pointed out in the paper as well. It concerns mainly material front tracking methods and treatment of boundary layer. Some ways to resolve existing constraints, as well as plans for future are presented.