3D SPH flow predictions and validation for high pressure die casting of automotive components

The geometric complexity and high fluid speeds involved in high pressure die casting (HPDC) combine to give strongly three-dimensional fluid flow with significant free surface fragmentation and splashing. A Lagrangian simulation technique that is particularly well suited to modelling HPDC is smoothed particle hydrodynamics (SPH). Materials are approximated by particles that are free to move around rather than by fixed grids, enabling the accurate prediction of fluid flows involving complex free surface motion.     

Modelling and validation: Casting of Al and TiAl alloys in gravity and centrifugal casting processes

Components which best utilise the properties of high temperature titanium alloys are characterised by thin sections of a few millimetres thickness and hundreds of millimetres length. These alloys however are difficult to work with, being highly reactive in a molten state, necessitating a low superheat during processing. Centrifugal casting is therefore utilised as a candidate production method, as under the centrifugal force, metal can rapidly fill thicknesses substantially less than a millimetre before it solidifies. However, due to the high liquid metal velocity developed there is a high risk of turbulent flow and of the trapping of any gas present within the liquid metal.This challenging application involves a combination of complex rotating geometries, significant centrifugal forces and high velocity transient free surface flows, coupled with simultaneous heat transfer and solidification. Capturing these interacting physical phenomena, free surface flows, trapped air and associated defects is a complex modelling task.Building upon earlier work on computational modelling the authors have previously described to capture and validate the fluid dynamics behaviour of rotating systems, this contribution considers the modelling and validation of such systems to capture the coupled flow and thermal solidification behaviour and associated defect development.A bench-mark test case is employed to validate the effect of solidification on the fluidity of an aluminium alloy. Validation is also performed against a series of casting experiments to establish the models ability to capture the filling process and predict defects due to air entrapment within the solidified metal.     

Application of Smoothed Particle Hydrodynamics for modelling gated spillway flows

Computational models of spillways are important for evaluating and improving dam safety, optimising spillway design and updating operating conditions. Traditionally, scaled down physical models have been used for validation and to collect hydraulic data. Computational fluid dynamics (CFD) models however provide advantages in time, cost and resource reduction. CFD models also provide greater efficiency when evaluating a range of spillway designs or operating conditions. Within the present literature, most studies of computational spillway models utilise a mesh-based method. In this work we use the particle based method of Smoothed Particle Hydrodynamics (SPH) to model weir flow through a four bay, gated, spillway system. Advantages of SPH for such modelling include automatic representation of the free surface flow behaviour due to the Lagrangian nature of the method, and the ability to incorporate complex and dynamic boundary objects such as gate structures or debris. To validate the SPH model, the reservoir water depth simulated is compared with a related physical study. The effect of SPH resolution on the predicted water depth is evaluated. The change in reservoir water level with discharge rates for weir flow conditions is also investigated, with the difference in simulated and experimental water depths found to range from 0.16% to 11.48%. These results are the first quantitative validation of the SPH method to capture spillway flow in three dimensions. The agreement achieved demonstrates the capability of the SPH method for modelling spillway flows.     

Extension of SPH to predict feeding,freezing and defect creation in low pressure die casting

Low pressure die casting is used to manufacture complex metal components where there is a need for high structural integrity. In this process, liquid metal is fed from below into the die used to form the component under a positive pressure. Smoothed particle hydrodynamics (SPH) is a meshfree Lagrangian method that has specific advantages for modelling such material forming applications. This paper describes extensions to the SPH method for predicting shrinkage of the cooling metal, tracking of oxide formation, prediction of feeding, solidification front dynamics and finally direct prediction of the residual pressure distribution in the solidified metal and of cavity defect formation. These are demonstrated using a simple two dimensional example which contains the essential features of an engine block.     

A corrected smoothed particle hydrodynamics method for solving transient viscoelastic fluid flows

In this work, a corrected smoothed particle hydrodynamics (CSPH) method is proposed and extended to the numerical simulation of transient viscoelastic fluid flows due to that its approximation accuracy in solving the Navier–Stokes equations is higher than that of the smoothed particle hydrodynamics (SPH) method, especially near the boundary of the domain. The CSPH approach comes with the idea of combining the SPH approximation for the interior particles with the modified smoothed particle hydrodynamics (MSPH) method for the exterior particles, this is because that the later method has higher accuracy than the SPH method although it also needs more computational cost. In order to show the validity of CSPH method to simulate unsteady viscoelastic flows problems, the planar shear flow problems, including transient Poiseuille, Couette flow and transient combined Poiseuille and Couette flow for the Oldroyd-B fluid are solved and compared with the analytical and SPH results. Subsequently, the general viscoelastic fluid based on the eXtended Pom–Pom (XPP) model is numerically investigated and the viscoelastic free surface phenomena of impacting drop are simulated by the CSPH for its extended application and the purpose of illustrating the ability of the proposed method. The numerical results are presented and compared with available solutions, which shows a very good agreement. All the numerical results show the higher accuracy and better stability of the CSPH than the SPH, especially for larger Weissenberg numbers.     

Modeling unsteady flow characteristics using smoothed particle hydrodynamics

Smoothed particle hydrodynamics (SPH) method has been extensively used to simulate unsteady free surface flows. The works dedicated to simulation of unsteady internal flows have been generally performed to study the transient start up of steady flows under constant driving forces and for low Reynolds number regimes. However, most of the fluid flow phenomena are unsteady by nature and at moderate to high Reynolds numbers. In this study, first a benchmark case (transient Poiseuille flow) is simulated to evaluate the ability of SPH to simulate internal transient flows at low and moderate Reynolds numbers (Re = 0.05, 500 and 1500). For this benchmark case, the performance of the two most commonly used formulations for viscous term modeling is investigated, as well as the effect of using the XSPH variant. Some points regarding using the symmetric form for pressure gradient modeling are also briefly discussed. Then, the application of SPH is extended to oscillating flows imposed by oscillating body force (Womersley type flow) and oscillating moving boundary (Stokes’ second problem) at different frequencies and amplitudes. There is a very good agreement between SPH results and exact solution even if there is a large phase lag between the oscillating pressure difference and moving boundary and the movement of the SPH particles generated. Finally, a modified formulation for wall shear stress calculations is suggested and verified against exact solutions. In all presented cases, the spatial convergence analysis is performed.     

Three dimensional modelling of lava flow using Smoothed Particle Hydrodynamics

The paper describes the use of the grid-free Smoothed Particle Hydrodynamics (SPH) method to investigate lava flow from volcanic eruptions using real three dimensional topography in the form of Digital Terrain Models (DTM). Heat transfer resulting from conduction and radiation and solidification of the lava modelled via a variable viscosity are coupled to the fluid flow solution. Simulations show that the run-out distance and the nature of the lava flow are affected significantly by the lava viscosity and that this is dependent on the scale of the volcanic eruption, with solidification effects strongest on the smallest scale. SPH appears to be a highly effective technique for predicting lava flow with very good representations of the fluid free surface, close interaction with the complex topography, easy inclusion of the thermal and solidification effects leading to very plausible flow predictions. The pile-up of the lava at the front as it solidifies and the subsequent deceleration of the flow are easily modelled by SPH.     

SPH modelling of fluid at the grain level in a porous medium

Computational modelling of the flow of fluids in porous media has traditionally been at a macroscopic level where the medium’s permeability and porosity are an input (from experiments for example). In many cases this is difficult, especially if the porous medium changes its solid structure as a function of time. This situation occurs in reactive systems such as “heap-leaching”, where biological and/or chemical solutions are introduced into the heap to dissolve or react with valuable materials. In this case, modelling fluid flow at the grain level is paramount and we show how this can be done with the SPH technique. We present three-dimensional SPH simulations of fluid flow in an idealised porous medium and show that the technique yields flows which are physically realistic. The permeability of the medium is then predicted.     

Extension of SPH to simulate non-isothermal free surface flows during the injection molding process

This article presents an extension of smoothed particle hydrodynamics (SPH) to non-isothermal free surface flows during the injection molding process. Specifically, we use the method presented by Xu and Yu, Appl. Math. Model. 48 (2017) pp. 384–409, in which the corrected kernel gradient is implemented to increase the computational accuracy and the Rusanov flux is introduced into the continuity equation to alleviate large and random pressure oscillations. To model non-isothermal free surface flows, a working SPH discretization of the temperature equation is derived. An enhanced treatment of the wall boundary is further developed, which can model arbitrary-shaped mold walls. The proposed SPH method is first validated by solving non-isothermal Couette flow and non-isothermal injection molding of a circular disc with a core and comparing the SPH results with those obtained by other numerical methods or experiments. We then extend the numerical method to non-isothermal injection molding of F-shaped and N-shaped cavities. The convergence of the method is examined with several different particle sizes. The effects of the operating conditions (e.g., injection temperature, temperature of the mold wall, and injection velocity) on the flow behavior are analyzed. All the results illustrate that the present SPH method is a powerful computational tool for simulations of non-isothermal free surface flows during the injection molding process.     

Mathematical and physical modelling of steel flow and solidification in twin-roll/horizontal belt thin-strip casting machines

Near-net-shape casting technology is one of the most important research areas in the iron and steel industry today. Driving forces for the development of this technology include a reduction in the number of operations needed for conventionally produced strip. This is especially true of hot rolling operations. The consequent reduction in investment cost when considering new industrial facilities, makes near-net-shape casting operations extremely attractive from a commercial standpoint. Various processes for near-net-shape casting of steel are currently being developed around the world. Of these processes, twin-roll casting machines represent a major area of concentration. We believe that one of the main issues concerning the design of twin-roll casters is the metal delivery system and its effect on the homogeneity of solid shell formation, segregation and surface quality. In the present work, computational fluid dynamics has been used to study different metal delivery systems for twin-roll casting (TRC) and horizontal belt casting (HBC) operations. The METFLO code has been adapted to simulate three-dimensional turbulent fluid flows, heat transfer and solidification in these types of machines. The enthalpy–porosity technique was used to couple fluid flow and solidification phenomena. Two configurations for metal delivery system have been studied to date for TRC: one is a conventional tubular nozzle with horizontal outlets in the directions of the side dams; the other is a slot nozzle with a vertical inlet stream. These simulations have been applied to a pilot caster being studied in Canada, with a roll radius of 0.30 m, producing steel strips with thicknesses ranging from 4 to 7 mm, at relatively low roll speeds ranging between 4 and 12 m/min. Different positions and penetrations of the nozzles in the liquid pool have also been analysed. It has been shown that a tubular nozzle leads to the formation of a non-uniform solid shell along the roll width. In both configurations, a thicker solid shell is formed close to the roll edges, due to the presence of the side dams. In the case of HBC, computations have been made for an extended nozzle metal delivery system, and preliminary water modelling tests carried out to confirm the flow delivery concepts proposed. In addition, instantaneous heat flux measurements to simulated belt substrates have been performed for the horizontal casting of aluminum strip that show somewhat similar characteristics to those measured for steel in the pilot TRC, in terms of transient peaks and decays.     

Transient thermal model for the hot chamber injection system in the pressure die casting process

This paper describes a three-dimensional numerical model that is used to predict the transient thermal behaviour of the metal injection system of a hot chamber pressure die casting machine. The behaviour of the injection system is considered in conjunction with that of the die. The Boundary Element Method (BEM) is used to model the transient thermal behaviour of the injection system elements and the die blocks. A perturbation approach is adopted. By adopting this approach, only those surfaces over which a significant transient variation in temperature occurs need be considered. The model assumes that a corresponding steady-state analysis has first been performed so that time-averaged thermal information is available. A finite element based technique is used to model the phase change of the liquid metal in the die cavity and in the injection system. At injection the nozzle and die are assumed to be instantly filled with liquid metal, however, a procedure is presented that attempts to model the heat transfer associated with the flow through the nozzle, gate, and runner regions during injection. Model predictions are compared against thermocouple readings and thermal images obtained from experimental tests. Good agreement is obtained between predicted and measured temperatures. The transient thermal behaviour of an existing hot chamber injection system is investigated in detail and recommendations for improved performance are made. In an attempt to improve the solidification pattern of the casting and the thermal behaviour of the injection system, a redesign of the experimental die is considered. The numerical predictions indicate that the redesign will have a beneficial effect on the solidification pattern of the casting, and on the performance of the injection system.     

Modelling confined multi-material heat and mass flows using SPH

Many applications in mineral and metal processing involve complex flows of multiple liquids and gases coupled with heat transfer. The motion of the surfaces of the liquids can involve sloshing, splashing and fragmentation. Substantially differing material properties are common. The flows are frequently complicated by other physical effects. Smoothed particle hydrodynamics (SPH) is a computational modelling technique that is ideally suited to such difficult flows. The Lagrangian framework means that momentum dominated flows and flows with complicated material interface behaviours are handled easily and naturally. To be able to model complex multi-physics flows, many aspects of SPH need to be explored. In this paper we describe developments that allow conductive and convective heat transfer to be modelled accurately for a sequence of idealised test problems.     

三维PTT黏弹性液滴撞击固壁面问题的改进SPH模拟

基于光滑粒子动力学(smoothed particle hydrodynamics, SPH)方法,对三维Phan-Thien Tanner(PTT)黏弹性液滴撞击固壁面问题进行了数值模拟.为了有效地防止粒子穿透固壁,且缩减三维数值模拟所消耗的计算时间,提出了一种适合三维数值模拟的改进固壁边界处理方法.为了消除张力不稳定性问题,采用一种简化的人工应力技术.应用改进SPH方法对三维PTT黏弹性液滴撞击固壁面问题进行了数值模拟,精细地捕捉了液滴在不同时刻的自由面,讨论了PTT黏弹性液滴不同于Newton(牛顿)液滴的流动特征,分析了PTT拉伸参数对液滴宽度、高度和弹性收缩比等的影响.模拟结果表明,改进SPH方法能够有效而准确地描述三维PTT黏弹性液滴撞击固壁面问题的复杂流变特性和自由面变化特征.     

Modelling of metal forging using SPH

In solid metal forming processes, such as forging, large distortions in the material present challenging problems for numerical simulation using grid based methods. Computations invariably fail after some level of mesh distortion is reached unless suitable re-meshing is implemented to cope with the mesh distortion arising from the material deformation. The issue of mesh distortion and the subsequent re-meshing are topics of much research for grid based methods. These problems can be overcome by using a mesh-less numerical framework. In this paper, the application of a mesh-less method called Smoothed Particle Hydrodynamics (SPH) for modelling three-dimensional complex forging processes is demonstrated. It is shown that SPH is a useful simulation method for obtaining insights into the material deformation and flow pattern during forging of realistic industrial components. The effect of process parameters and material properties on the quality of the forged component is evaluated via SPH simulations. This includes the determination of forging force required for adequate die filling which is an important criterion for die designs. Material hardening, controlled by the degree of heat treatment, is found to have a profound effect on the material deformation pattern and the final product. Forging defects such as incomplete die filling, asymmetry in forged components, flashing and lap formation are shown to be predicted by SPH. SPH can thus potentially be used both for assessment of the quality of forged products and evaluation of prototype forging system designs.     

A three-dimensional fluid flow model for puddle formation in the single-roll rapid solidification process

The single-roll rapid solidification process (SRRSP) is considered to be a process of perspective to produce a Fe-Si-B ribbon of amorphous microstructure and near net shape products such as thin strips of stainless steel. The condition of a melt puddle between the nozzle and rotating wheel in the single-roll rapid solidification process significantly affects the quality and dimensional uniformity of the products as well as the smoothness of the operation. The purpose of this study was to develop a three-dimensional fluid flow analysis system to model the formation of puddle and flow conditions of molten metal in the puddle for the single-roll rapid solidification processes which include the planar flow casting (PFC) process and the single-roll strip casting process. The model is based on a computational fluid dynamics technique called the SOLA-VOF scheme, which possesses the capability of treating transient fluid flow problems with the evolution of free boundaries. Furthermore, the SOLA-VOF scheme is extended from two dimensions to three dimensions. The simulated results reveal how the melt puddle is formed between the nozzle and the rotating substrate and its corresponding fluid flow behavior for the PFC process as well as the single-roll strip casting process. The test results also demonstrate that two-dimensional analysis cannot properly consider the actual flow condition in the puddle.     

A coupled NMM-SPH method for fluid-structure interaction problems

The main challenges in the numerical simulation of fluid–structure interaction (FSI) problems include the solid fracture, the free surface fluid flow, and the interactions between the solid and the fluid. Aiming to improve the treatment of these issues, a new coupled scheme is developed in this paper. For the solid structure, the Numerical Manifold Method (NMM) is adopted, in which the solid is allowed to change from continuum to discontinuum. The Smoothed Particle Hydrodynamics (SPH) method, which is suitable for free interface flow problem, is used to model the motion of fluids. A contact algorithm is then developed to handle the interaction between NMM elements and SPH particles. Three numerical examples are tested to validate the coupled NMM-SPH method, including the hydrostatic pressure test, dam-break simulation and crack propagation of a gravity dam under hydraulic pressure. Numerical modeling results indicate that the coupled NMM-SPH method can not only simulate the interaction of the solid structure and the fluid as in conventional methods, but also can predict the failure of the solid structure.     

Computational fluid dynamics modelling of gas jets impinging onto liquid pools

Gas jets impinging onto a gas–liquid interface of a liquid pool are studied using computational fluid dynamics modelling, which aims to obtain a better understanding of the behaviour of the gas jets used metallurgical engineering industry. The gas and liquid flows are modelled using the volume of fluid technique. The governing equations are formulated using the density and viscosity of the “gas–liquid mixture”, which are described in terms of the phase volume fraction. Reynolds averaging is applied to yield a set of Reynolds-averaged conservation equations for the mass and momentum, and the k–ε turbulence model. The deformation of the gas–liquid interface is modelled by the pressure jump across the interface via the Young–Laplace equation. The governing equations in the axisymmetric cylindrical coordinates are solved using the commercial CFD code, FLUENT. The computed results are compared with experimental and theoretical data reported in the literature. The CFD modelling allows the simultaneous evaluation of the gas flow field, the free liquid surface and the bulk liquid flow, and provides useful insight to the highly complex, and industrially significant flows in the jetting system.     

A conservative SPH scheme using exact projection with semi-analytical boundary method for free-surface flows

This paper presents a novel SPH scheme for modelling incompressible and divergence-free flow with a free surface (IDFSPH) associated with semi-analytical wall boundary conditions. In line with the projection method, the velocity field is decoupled from the pressure field in the momentum equation. A Poisson equation, serving as the pressure solver, is obtained by which pressure field is decoupled completely from the velocity field. In particular, an exact projection scheme is deployed to fulfil the requirement of the divergence-free velocity field. The condition of incompressibility is satisfied by iteratively updating the density field till the convergence. The two-equation k–ε model is employed to describe the turbulence effects in Newtonian flows. It is shown that the discretised SPH schemes have the feature of both linear and angular momentum conservations. The semi-analytical wall method implements the appropriate integrals to evaluate the boundary contributions to the mass and momentum equations. In comparison to the boundary particle methods, it can greatly enhance the feasibility and efficiency with the complex geometries. The algorithm presented within this paper is applied to several academic test cases for which either analytical results or simulations with other methods are available. The comparisons verify that this scheme is provided with convincing efficiency and extensive applicability.     

A decoupled finite particle method for modeling incompressible flows with free surfaces

Smoothed particle hydrodynamics (SPH) is a meshfree Lagrangian particle method, and it has been applied to different areas in engineering and sciences. One concern of the conventional SPH is its low accuracy due to particle inconsistency, which hinders the further methodology development. The finite particle method (FPM) restores the particle consistency in the conventional SPH and thus significantly improves the computational accuracy. However, as pointwise corrective matrix inversion is necessary, FPM may encounter instability problems for highly disordered particle distribution. In this paper, through Taylor series analyses with integration approximation and assuming diagonal dominance of the resultant corrective matrix, a new meshfree particle approximation method, decoupled FPM (DFPM), is developed. DFPM is a corrective SPH method, and is flexible, cost-effective and easy in coding with better computational accuracy. It is very attractive for modeling problems with extremely disordered particle distribution as no matrix inversion is required. One- and two-dimensional numerical tests with different kernel functions, smoothing lengths and particle distributions are conducted. It is demonstrated that DFPM has much better accuracy than conventional SPH, while particle distribution and the selection of smoothing function and smoothing length have little influence on DFPM simulation results. DFPM is further applied to model incompressible flows including Poiseuille flow, Couette flow, shear cavity and liquid sloshing. It is shown that DFPM is as accurate as FPM while as flexible as SPH, and it is very attractive in modeling incompressible flows with possible free surfaces.