Numerical Simulation of Mold Filling and Temperature Field on Shell-Mold Chilled Casting Process

2008 ◽  
Vol 5 (8) ◽  
pp. 1622-1626
Author(s):  
Ping Li ◽  
Qizhou Cai ◽  
Bokang Wei ◽  
Liliang Chen ◽  
Ruixiang Liu
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Casting Process ◽  
Mold Filling ◽  
Shell Mold

Numerical Simulation of Chilled Cast Iron Camshaft in Sand Casting Process

2010 ◽  
Vol 44-47 ◽  
pp. 117-121
Author(s):  
Bin Feng He ◽  
Zhu Qing Zhao
Keyword(s):  
Numerical Simulation ◽  
Cast Iron ◽  
Solidification Process ◽  
Casting Process ◽  
Mold Filling ◽  
Sand Casting ◽  
Simulation Results ◽  
Improved Technology ◽  
Filling And Solidification ◽  
Chilled Cast Iron

There are many kinds of casting defects such as insufficient pouring, cooling separation, crack, and shrinkage and soon on were formed in the mold filling and the solidification process, which affect the final casting performance. Based on the mathematical models of mold filling and solidification process, the numerical simulation of chilled cast iron camshaft in sand casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkages were predicted. According to the simulation results, an improved technology is proposed, and the shrinkages were eliminated efficiently. The simulation results are in good agreement with practical.

Numerical simulation on sprue distributions during cladding casting process

2016 ◽  
Vol 26 (8) ◽  
pp. 2340-2354 ◽  
Author(s):  
Xing Han ◽  
Haitao Zhang ◽  
Bo Shao ◽  
Dongtao Wang ◽  
Longgang Cheng ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Casting Process ◽  
Mathematic Model ◽  
Melt Flow ◽  
Content Type ◽  
Metallurgical Bonding ◽  
Flow Heat ◽  
Simulation Results ◽  
Interface Bonding Strength

Purpose The purpose of this paper is to investigate the influence of sprue distributions on the flow field and temperature field of the cladding casting process and verify the simulation results by experiments. Design/methodology/approach A steady-state mathematic model for the coupling of fluid flow, heat transfer and solidification to describe the process of cladding casting was present. The effect of sprue distributions on melt flow and temperature field was discussed. Based on the numerical simulation results, the cladding billet was prepared successfully. Moreover, the model has been verified against by temperature measurements during the cladding casting process. Findings There is a good agreement between the measured and calculated results. The homogeneity of melt flow determines the formability of cladding billets and circular temperature difference affects the bonding of the two alloys. The AA4045/AA3003 cladding billet with no defects in size of f140/f110 mm was fabricated successfully. The alloy elements diffused across the interface and formed diffusion layer with a thickness of 15 µm. The interface bonding strength is higher than the tensile strength of AA3003, indicating the metallurgical bonding between two alloys. Research limitations/implications The casting parameters are limited to the aluminum alloy cladding billet in size of f140/f110 mm in this paper. Originality/value There are few reports of cladding billet, which are used to prepare condense pipes of automotive engines. The effect of distribution schemes on the cladding casting process is rarely studied.

Numerical Simulation and Optimization on Casting Technique of HT200 Flywheel

2010 ◽  
Vol 97-101 ◽  
pp. 2553-2557 ◽  
Author(s):  
Bin Feng He ◽  
Guo Fa Mi ◽  
Shuang Shuang He
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Casting Process ◽  
Gating System ◽  
Casting Technique ◽  
Simulation And Optimization ◽  
Casting Yield ◽  
Simulation Results

The Z-CAST software was employed to simulate the casting process of gray cast-iron flywheel. Shrinkage was predicted through analyzing the temperature field and the flow field. According to the simulation results, the gating system was improved to eliminate shrinkage, and the thin, wide ingate was shown that can reduce the shrinkage and increase casting yield.

Numerical Simulation and Die Casting Process for Cylinder

2012 ◽  
Vol 490-495 ◽  
pp. 2362-2365
Author(s):  
Yong Huang ◽  
Yue Dong ◽  
Xiao Ming Du
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Temperature Field ◽  
Die Casting ◽  
Casting Process ◽  
Processing Parameters ◽  
Mould Temperature ◽  
Pouring Temperature ◽  
Die Casting Process ◽  
Filling And Solidification

Filling and solidification for aluminum alloy packing block in die casting were simulated by numerical simulation. Distribution and change of temperature field as well as velocity field were visualized. The desirable processing parameters can be obtained with pouring temperature of 620°C and mould temperature of 180°C as well as shot velocity of 4m/s. The qualified products were obtained on the basis of the optimized die-casting parameters.

Research of the Interpolation Method Applied to the Numerical Simulation of the Casting Filling Process

2014 ◽  
Vol 1037 ◽  
pp. 369-372
Author(s):  
Xiao Chong Lv ◽  
Ya Jun Yin ◽  
Jian Xin Zhou
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Interpolation Method ◽  
Interpolation Formula ◽  
Mold Filling ◽  
Casting Simulation ◽  
Filling Process ◽  
Process Comparison ◽  
Temperature Filed ◽  
Last Stage

With the development of computer technology, casting simulation plays an increasingly important role in foundry production. VOF (Volume of Fluid) method which tracks free surfaces is widely used in casting simulation because it is simple to solve and easy to achieve. However, in the last stage of mold filling process, the solution speed of VOF method is very slow because the space to fill becomes smaller. To solve this problem, interpolation formula is applied to the calculation of temperature field and an interpolation method to calculate the last part of temperature field in mold filling process is presented in this paper. The solution is to calculate temperature field of unfilled grids based on the temperature filed of filled grids at the last stage of filling process. Comparison between the results of interpolation method and theoretical calculation illustrates the rationality of the interpolation temperature field in this paper. Numerical simulations of actual castings indicate that the interpolation method can greatly improve the speed of getting temperature field under a certain accuracy. This paper has important implications to the calculation of numerical simulation in mold filling process.

Numerical Simulation of Die-Casting Magnesium Alloy Impeller with the Central Gating System

2011 ◽  
Vol 55-57 ◽  
pp. 2126-2129
Author(s):  
Xiao Chun Ma ◽  
Yi Qiang Zhuang ◽  
Ying Qi Tao
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Magnesium Alloy ◽  
Simulation Analysis ◽  
Die Casting ◽  
Casting Process ◽  
Gating System ◽  
Element Analysis ◽  
Pump Impeller ◽  
Die Casting Process

AZ91D magnesium alloy used as the automotive cooling system’s pump impeller material, using the finite element analysis software ProCAST to numerical simulation for the temperature field and the flow field of die-casting process, analyzed the defects causes of magnesium alloy die-casting, and then determined the gating system. Based on the results of numerical simulation analysis, the design of ingate of the gating system set on central department is reasonable. It's benefit for smooth filling of liquid metal and uniforming the temperature field distribution, so as to reduce casting porosity, cold shut and shrinkage defects.

Numerical Modeling on Sand Casting Process of a Wind Turbine Part

2011 ◽  
Vol 121-126 ◽  
pp. 1367-1371 ◽  
Author(s):  
Qing Ming Chang ◽  
Yin Kai Yang ◽  
Xia Chen ◽  
Chang Jun Chen ◽  
Si Qian Bao
Keyword(s):  
Numerical Simulation ◽  
Numerical Modeling ◽  
Wind Turbine ◽  
Research Work ◽  
Casting Process ◽  
Mold Filling ◽  
Sand Casting ◽  
Shrinkage Cavity ◽  
Pouring Temperature ◽  
Filling And Solidification

In this research work, ProCAST software is employed to study the sand casting process of a box-type part for wind turbine. The casting part is big in size, non-uniform in wall thickness, and heavy in some local positions. Shrinkage cavity and porosity are very likely to from at these locations. By numerical simulation, the influence of the parameters such as pouring temperature, chills, riser on mold filling and solidification is analyzed. Simulation researches reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced.

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