Computer-Aided Engineering (CAE) Simulation for the Robust Gating System Design: Improved Process for Investment Casting Defects of 316L Stainless Steel Valve Housing

The thin wall stainless steel castings is difference to ordinary steel castings in foundry technology. This paper discussed the problems of thin wall stainless steel castings which appearing in the flow controlling board for warm-air pipe, and put forward the foundry technology of this stainless steel castings based on the principle of directional solidification and fast pouring mechanism. According to the theory, twin gating system has been designed for the controlling board castings, and two ladles are pouring into the open twin gating system at the same time. The shrinkage of finally congealing part was fed by two risers. The practice has shown that the design is feasible, there is not cold shut, misrun, scab, and oxidizing for the castings, and the requirements of mechanical properties can be met.

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Prediction of Shrinkage Porosity in Femoral Stem of Titanium Investment Casting

Archives of Foundry Engineering ◽

10.1515/afe-2016-0102 ◽

2016 ◽

Vol 16 (4) ◽

pp. 157-162 ◽

Cited By ~ 3

Author(s):

◽

Muslim Mahardika ◽

A. Syamsudin ◽

Keyword(s):

System Design ◽

Investment Casting ◽

Pure Titanium ◽

Femoral Stem ◽

Solidification Process ◽

Shrinkage Porosity ◽

Commercially Pure Titanium ◽

Gating System ◽

Cross Section Area ◽

System Designs

Abstract Design of gating system is an important factor in obtaining defect-free casting. One of the casting defects is a porosity caused by internal shrinkage in solidification process. Prediction of the internal shrinkage porosity in the femoral stem of commercially pure titanium (CP-Ti) is investigated based on the gating system design. The objective of this research is to get the best gating system between three gating system designs. Three gating system designs of the femoral stem were simulated in an investment casting method. The internal shrinkage porosity occurs on the largest part and near the ingate of the femoral stem. The gating system design that has ingates cross section area: 78.5; 157; and 128.5 mm2 has the least of the internal shrinkage porosity. This design has the most uniform solidification in the entire of the femoral stem. An experiment is conducted to validate the simulation data. The results of internal shrinkage porosity in the three gating system designs in the simulation were compared with the experiment. Based on the comparison, the trend of internal shrinkage porosity at the three gating system designs in the simulation agrees with the experiment. The results of this study will aid in the elimination of casting defect.

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Pushing the Design Envelope with CAE

Mechanical Engineering ◽

10.1115/1.1998-dec-6 ◽

1998 ◽

Vol 120 (12) ◽

pp. 72-73 ◽

Cited By ~ 1

Author(s):

Marc Halpern

Keyword(s):

Computer Aided Engineering ◽

Major Influence ◽

Design Decisions ◽

Engineering Programs ◽

Design Changes ◽

Computer Aided ◽

The Status ◽

Cash Benefits ◽

Cae Simulation

This article focuses on the growing role of computer-aided engineering programs for the design of electronic packaging. While computer-aided engineering (CAD) clearly offers the potential to improve products and cut manufacturing costs and time, those who have adopted CAE are facing significant challenges in making it work. Historically, CAE has failed to deliver results fast enough to exert a major influence on design decisions. Instead, corporations have used finite-element results to validate previously determined designs. But because design changes later can cost more than correct up-front decisions, CAE simulation can offer cash benefits when it has a role in the initial stages of product design. Technical staff leaders must translate objectives into CAE work that is efficient and effective. The status of the measurements must always be available, in order to monitor progress.

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Investment Casting Defects of a Turbine Nozzle Made by K465 Alloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.898.487 ◽

2017 ◽

Vol 898 ◽

pp. 487-491

Author(s):

Yang Li ◽

Pei Jia Li ◽

Xing Fu Chen ◽

Hao Ran Liu ◽

Jian Tao Wu ◽

...

Keyword(s):

Investment Casting ◽

Solidification Process ◽

Casting Defects ◽

Gating System ◽

Grain Refiner

The investment casting defects in a turbine nozzle with size of φ 331mm and thickness 0.7 mm and the number of vanes of 31 have been studied in two aspects, which were the porosity of the turbine nozzle’s inner cone and the cracks of the turbine nozzle’s vanes. ProCAST software was used to analyze the nozzle’s solidification process. A suitable gating system was used to solve porosity issues effectively by changing local thickness and improving solidification conditions. The crack on the nozzle’s vanes was studied and a kind of grain refiner was used to solve crack issues by improving shell strength. In order to manufacture castings with high metallurgical quality and meet the design and use demands, a reasonable gating system and a moderate shell process were used.

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A Transient Computer Aided Engineering Model for Automobile Heater System Design

10.4271/2000-01-1274 ◽

2000 ◽

Cited By ~ 1

Author(s):

H. S. Hu ◽

D. C. Huang ◽

C. Wojdyla

Keyword(s):

System Design ◽

Computer Aided Engineering ◽

Engineering Model ◽

Computer Aided

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A system for computer-aided gating design for multi-cavity die-casting dies

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415614727 ◽

2015 ◽

Vol 231 (11) ◽

pp. 1983-1999 ◽

Cited By ~ 2

Author(s):

Vijay Kumar ◽

Jatinder Madan

Keyword(s):

System Design ◽

Computer Aided Design ◽

Die Casting ◽

Casting Process ◽

Manufacturing Cost ◽

Gating System ◽

Industrial Case Study ◽

Efficient Manner ◽

Die Casting Die ◽

Computer Aided

The gating system design for a die-casting die is a non-trivial task that involves a number of steps and computations, in which many factors related to part design, material, and process need to be accounted. In case of a multi-cavity die-casting die, the non-triviality of the gating system design increases manifold. The main contribution of this article is to develop a computer-aided system for design of gating system for multi-cavity die-casting dies. The proposed system applies design knowledge and rules, accounting for various influencing factors to design gating system elements and generate their computer-aided design models in an efficient manner. To demonstrate the capabilities of the developed system, the results for an industrial case study part are presented. We expect that the proposed system would help reduce manufacturing cost and lead time, alongside bridging gaps between design and manufacturing of the die-casting process.

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