Defect elimination in green sand casting using simulation techniques: A case study

2020 ◽  
Vol 11 (05) ◽  
pp. 2050049
Author(s):  
Sarabjit Singh ◽  
Neeraj Sharma ◽  
Rajesh Khanna
Keyword(s):  
Molten Metal ◽  
Reynolds Numbers ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Sand Casting ◽  
Green Sand ◽  
Simulation Techniques ◽  
Sand Erosion ◽  
Full Production ◽  
Porosity Defects

The Reynolds number of molten metal flowing mold cavity causes bulk turbulence and is the main cause of defects like shrinkage porosity and sand erosion. Machined housings with shrinkage porosity at critical bearing bores and surface made the casting useless. In old gating casting areas of perimeters 290[Formula: see text]mm and 264[Formula: see text]mm of transmission housing, Reynolds numbers were observed as 16307 and 13806, respectively using simulation software. Data were collected from experiments to change casting area perimeters from 785[Formula: see text]mm and 785[Formula: see text]mm along with the addition of overlap area. New Reynolds numbers at two locations were observed as 3705 and 3393, respectively. Molten metal pressure, velocity and temperature results were related for final shrinkage results of the components on full production. The purpose of the study is to reduce shrinkage and porosity defects in green sand casting part using MAGMAS simulation software. High outcome was the reduction of casting machining rejection in transmission housing casting from 5.8% 0.7% with savings of approximately 0.13 million USD over the period of 14 months. Implications of this work include casting defects study and reduction in different grades and weight range.

Casting Process Solutions Optimization of LFC Forklift Box

2014 ◽  
Vol 571-572 ◽  
pp. 1091-1096
Author(s):  
Guang Sheng Zhang ◽  
Fei Zhang
Keyword(s):  
Orthogonal Experiment ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Technology Program ◽  
Original Process ◽  
Porosity Defects ◽  
Process Solutions ◽  
Technology Solution ◽  
Casting Simulation Software

There are many advantages in producing forklift box through the LFC. However, we found shrinkage porosity defects in the interior of castings through simulating the original process by ProCAST casting simulation software. Therefore, we analyzed the defects and improved the technology program. firstly, increased riser in position of shrinkage, Secondly, changed the filling’s way, lastly, selected the best temperature and vacuum by the orthogonal experiment and determined the best technology solution. we found the shrinkage porosity defects have been removed by the improved process. We found the production consistent with the simulation results through verification. Therefore we verify the accuracy of the ProCAST.

scholarly journals POTENSI PASIR LOKAL TANJUNG BINTANG PADA ALUMINIUM SAND CASTING TERHADAP POROSITAS PRODUK HASIL COR ALUMINIUM

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
Yusup Hendronursito ◽  
Yogi Prayanda
Keyword(s):  
Water Content ◽  
Clay Content ◽  
Sand Casting ◽  
Metal Casting ◽  
Green Sand ◽  
Aluminium Casting ◽  
Porosity Defects ◽  
Varied Level

Green sand is one of the most important components in the process of metal casting. The sand in Indonesia region is varied level of subtlety, size of sand, and shape of sand. Green sand used in the process of metal casting is possible can affect the quality of casting product. This aims to determine the potential of Tanjung Bintang sand as green sand and the quality of the product in terms of porosity defects. The research was conducted by varying sand river from Tanjung Bintang and sand from Maringgai. Composition made varying  is 100%,75%, 50%, and 25% Tanjung Bintang sand compared Maringgai sand with bentonit and water is 10% and 5% constantly .The Examine of the green sand by SNI 15-0312-1989 among other water content, clay content, Grain Finnest Number (GFN), Shape of grain. The result said aluminium casting product with  50% Tanjung Bintang sand has the lowest value of porosity, 5.08% and the higher value with 75% composition of Tanjung Bintang sand, 6.98%.

scholarly journals POTENSI PASIR LOKAL TANJUNG BINTANG PADA ALUMINIUM SAND CASTING TERHADAP POROSITAS PRODUK HASIL COR ALUMINIUM

2016 ◽  
Vol 1 (2) ◽  
pp. 60-68
Author(s):  
Yusup Hendronursito ◽  
Yogi Prayanda
Keyword(s):  
Water Content ◽  
Clay Content ◽  
Sand Casting ◽  
Metal Casting ◽  
Green Sand ◽  
Aluminium Casting ◽  
Porosity Defects ◽  
Varied Level

Green sand is one of the most important components in the process of metal casting. The sand in Indonesia region is varied level of subtlety, size of sand, and shape of sand. Green sand used in the process of metal casting is possible can affect the quality of casting product. This aims to determine the potential of Tanjung Bintang sand as green sand and the quality of the product in terms of porosity defects. The research was conducted by varying sand river from Tanjung Bintang and sand from Maringgai. Composition made varying  is 100%,75%, 50%, and 25% Tanjung Bintang sand compared Maringgai sand with bentonit and water is 10% and 5% constantly .The Examine of the green sand by SNI 15-0312-1989 among other water content, clay content, Grain Finnest Number (GFN), Shape of grain. The result said aluminium casting product with  50% Tanjung Bintang sand has the lowest value of porosity, 5.08% and the higher value with 75% composition of Tanjung Bintang sand, 6.98%.

scholarly journals Precipitation behavior near shrinkage porosity in a large sand casting of Haynes 282 alloy

Materialia ◽  
2021 ◽  
Vol 15 ◽  
pp. 101035
Author(s):  
Ling Wang ◽  
Kinga A. Unocic ◽  
Peter F. Tortorelli ◽  
Michael Santella ◽  
Xiang  (Frank) Chen
Keyword(s):  
Shrinkage Porosity ◽  
Sand Casting ◽  
Precipitation Behavior

Numerical Simulation of Filling and Solidification in Sand Casting by Procast

2013 ◽  
Vol 791-793 ◽  
pp. 550-553 ◽  
Author(s):  
Dong Dong Han ◽  
Cheng Jun Wang ◽  
Juan Chang ◽  
Lei Chen ◽  
Huai Bei Xie
Keyword(s):  
Numerical Simulation ◽  
Heat Dissipation ◽  
Solidification Process ◽  
Simulation Software ◽  
Sand Casting ◽  
Production Costs ◽  
Raw Material ◽  
Casting Defects ◽  
Three Dimension ◽  
Filling And Solidification

At present, pulley produced in China has been able to meet the demand of domestic and international markets. But there are many problem of the pulley industry in our country, such as too many production enterprises and the low level of export products. And as components of drive system are light weight and raw material price of pulley casting are rising, manufacturing requirements of the pulley are also more and more high. Aiming at the casting defects of pulley that enterprise current product, pulley casting blank model of common material HT250 be made by three-dimension software, numerical simulation of filling and solidification process for pulley sand casting by the casting simulation software Procast, the size and location of the various casting defects were forecasted and analyzed, reflecting the pulley filling and solidification process of the actual situation, due to the thicker pulley rim and less heat dissipation, position of shrinkage is close to the middle of rim [, a method of eliminating defects is proposed to realize sequential solidification, and thus to minimize porosity shrinkage and improve casting performance and reduce casting time and reduce production costs.

Simulation on the Thixocasting Process of the Turbocharger Impellers and Selection of the Viscosity Models

2014 ◽  
Vol 217-218 ◽  
pp. 219-224 ◽  
Author(s):  
Fan Zhang ◽  
Xiao Gang Hu ◽  
Da Quan Li ◽  
You Feng He ◽  
Xiao Jing Xu ◽  
...  
Keyword(s):  
Solid Fraction ◽  
High Speed ◽  
High Viscosity ◽  
Shrinkage Porosity ◽  
Die Design ◽  
Semisolid Slurry ◽  
Filling Process ◽  
Viscosity Models ◽  
Defect Control ◽  
Porosity Defects

The thixocasting technology is chosen to produce the turbocharger impellers as it is capable of producing castings with high precision dimension, free of oxide and shrinkage porosity defects and therefore long service life. The thixocasting turbocharger impellers have the similar mechanical property to those produced by forging and machine processes, but much less costs. In the thixocasting process, the semisolid slurry with certain solid fraction is injected into mould at a high speed. Since high viscosity and thixotropic characteristics, the semisolid slurry reveals unique flow condition and characteristics in the filling process. So, its very desirable for the die design, process optimization, and defect control to visualize the high-speed filling process of semisolid slurry by numerical simulation. In this paper, several commonly used viscosity models for semisolid slurry are analysed. The Power law cut-off model (PLCO) model is selected to simulate the filling process in the thixocasting process of the impellers of 319s alloy, compared with actual results by partial filling testing. The causes of the casting defects are also analysed, indicating that the simulation results can accurately reproduce the filling process of semisolid slurry, and PLCO model is a successful choice for simulating the filling process of semisolid slurry with high solid fraction.

Study on Local Extrusions' Effects on Improvement of Die Casting Prismatic Parts' Forming Quality

2013 ◽  
Vol 312 ◽  
pp. 475-479
Author(s):  
Wei Gang Zheng ◽  
Cun Hong Yin ◽  
Yu Hong Yuan ◽  
Zhen Min Pan ◽  
Chao Tang
Keyword(s):  
Mechanical Properties ◽  
Die Casting ◽  
Casting Process ◽  
Extrusion Process ◽  
Shrinkage Porosity ◽  
Shrinkage Cavity ◽  
Prismatic Parts ◽  
Porosity Defects ◽  
Die Casting Process ◽  
Casting Production

This paper analyzes traditional die casting process to find out the reasons that cause shrinkage cavity and porosity defects in casting. An optimized process of die casting by using local extrusion is proposed. A device used in local extrusion which realizes forcing compensating contraction on key parts of crankcase is designed and the parameters of local extrusion process are discussed. Compared the mechanical properties and microstructure of local extrusion used in die casting production with traditional. It shows that local extrusion used in die casting production can not only achieve the aim eliminating shrinkage porosity and cavity of a casting but also can refine grain to improve the mechanical properties.

Welding Robot Dynamic Simulation

2013 ◽  
Vol 849 ◽  
pp. 316-320 ◽  
Author(s):  
Xue Jun Zhang ◽  
Xue Jin Zhang
Keyword(s):  
System Analysis ◽  
Simulation Software ◽  
Prototype Model ◽  
Welding Robot ◽  
Drive Mode ◽  
Structure And Motion ◽  
Simulation Techniques ◽  
Mode Design ◽  
Adams Simulation ◽  
Motion Features

In this paper, the history and present conditions of welding robot were summarized in domestic situation and foreign situation, the latest development in technology was discussed. According to the structure and motion features of welding robots, using the UG simulation techniques can help us to establish the virtual prototype model of the robot easily, which can achieve the movement of the whole system analysis, dynamic analysis and so on. In this paper, the result of the application ADAMS simulation software is that the simulation mode provide reference for optimize the structure and drive mode design. It also was provided a possible scheme for the final optimal design.

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