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The atomization of molten aluminum when injected during high-pressure die casting is analyzed to determine its effect in enhancing the strength of the product being cast. In the previously reported first step of this study, molten aluminum was injected into open space and its atomization was observed photographically. Now in the second step of the study, a simulation is conducted to determine how the molten aluminum becomes atomized at the injection nozzle (gate) and how this atomized material flows and fills the cavity. A new simulation method is developed based on large-eddy simulation coupled with the volume-of-fluid method. The simulation system is verified by comparing its output with photographs taken in the first step of the study. Simulations are then conducted using an approximation of a real cavity to visualize how it is filled by the atomized molten aluminum.

Amidst the growing concerns for the global environment and the escalating demands for low exhaust emissions and high fuel economy small motorcycles, the electronically controlled fuel injection system (hereafter referred to as FI system) is making its appearance as an effective device to reduce emissions while improving fuel economy by precisely controlling the air-to-fuel ratio. Fuel injectors and fuel pumps currently used in small motorcycle FI systems were originally derived from multi-cylinder engine automobile and large motorcycle FI system components, and therefore have not been necessarily suitable for small motorcycle application.