Air entrapment during mold filling critically affects porosity and overall casting quality in High Pressure Die Casting. This study assesses the feasibility of applying the vof method within OpenFOAM to simulate compressible, turbulent mold filling in a thin-walled geometry. Three-dimensional simulations with the "compressibleInterFoam" solver were carried out under ambient initial cavity conditions, using both laminar flow and the k-e turbulence model. The free surface dynamics were examined across a range of inlet velocities to evaluate their influence on interface morphology, cavity pressurization, and gas entrapment. To quantify these effects, three evaluation criteria were introduced: the TIFSA as a measure of oxidation risk, the TMVF as an indicator of filling continuity and air entrapment, and the TIVF as a proxy for surface loading. Results show that turbulence modeling accelerates pressurization and limits the persistence of entrapped gas, with velocity governing the balance between smooth filling, turbulent breakup, and exposure duration. Comparison with experimental casting trials, including CT based porosity analysis and photogrammetric surface evaluation, validated that the model captures key defect mechanisms and provides quantitative guidance for process optimization.

翻译：高压压铸过程中，模具填充阶段的气体卷入对孔隙率和铸件整体质量具有关键影响。本研究评估了在OpenFOAM中应用VOF方法模拟薄壁几何结构中可压缩湍流模具填充的可行性。在初始型腔环境条件下，采用"compressibleInterFoam"求解器进行了三维模拟，分别使用了层流模型和k-e湍流模型。通过改变入口速度范围研究了自由表面动力学，以评估其对界面形态、型腔增压和气体卷入的影响。为量化这些效应，引入了三项评估标准：作为氧化风险度量的TIFSA、作为填充连续性与气体卷入指标的TMVF，以及作为表面载荷代理的TIVF。结果表明，湍流建模加速了增压过程并限制了卷入气体的持续存在，而速度则主导了平稳填充、湍流破碎与暴露持续时间之间的平衡。通过与实验铸造试验（包括基于CT的孔隙率分析和摄影测量表面评估）的比较，验证了该模型能够捕捉关键缺陷机制，并为工艺优化提供定量指导。