'Designing-in' controlled filling using numerical simulation for gravity sand casting of aluminium alloys

2006 ◽  
Vol 19 (1) ◽  
pp. 18-25 ◽  
Author(s):  
J.-C. Gebelin ◽  
M. R. Jolly ◽  
F.-Y. Hsu
Keyword(s):  
Numerical Simulation ◽  
Aluminium Alloys ◽  
Sand Casting

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.

Basic Experimental and Numerical Investigations on Chip Pressing

2013 ◽  
Vol 554-557 ◽  
pp. 630-637 ◽  
Author(s):  
Martin Grüner ◽  
Marion Merklein
Keyword(s):  
Numerical Simulation ◽  
Aluminium Alloys ◽  
Testing Machine ◽  
Material Model ◽  
Extrusion Process ◽  
Milling Process ◽  
Numerical Investigations ◽  
Compression Direction ◽  
Universal Testing ◽  
The Stability

Aluminium alloys show a great potential for lightweight constructions due to their high strength and low density but the production of this material is very energy consuming. Also the recycling of aluminium alloys, e.g. chips from the milling process, shows different challenges. Beside contamination by cooling lubricant and oxidation of the surface of the chips the melting and rolling process for new semi finish products needs a high amount of energy. TEKKAYA shows a new approach for recycling of aluminium alloy chips by an extrusion process at elevated temperatures producing different kinds of profiles. A new idea is the production of components directly out of chips using severe plastic deformation for joining of the chips similar to the accumulative roll bonding process in sheet metal forming. In a first approach aluminium alloy chips out of a milling process were uniaxial compressed with different loads inside an axisymmetric tool installed in a universal testing machine. The compressed chip disks subsequently were tested with two experiments to gain information on their stability. First experiment is a disk compression test with the disk standing on its cylindrical surface, giving information on the stability perpendicular to the compression direction. Second experiment is a stacked disk compression test with three disks to investigate the stability parallel to compression direction. During all three tests force and displacement values are recorded by the universal testing machine. These data are also processed to calculate or identify input parameters for the numerical investigations. For numerical simulation ABAQUS in conjunction with the Drucker-Prager-Cap material model, which is often used for sintering processes, seems to be a good choice. By numerical simulation of the experiments and comparison with the experiments input parameters for the material model can be identified showing good accordance. This material model will be used in future numerical investigations of an extrusion process to identify tool geometries leading to high strains inside the material and by this to an increased stability of the parts.

scholarly journals Numerical Simulation of Sand Casting of an Aluminium Part

2011 ◽  
pp. 0445-0446
Author(s):  
George Christopher Vosniakos ◽  
Anastasia Vassiliou ◽  
Spyridon Tsekouras
Keyword(s):  
Numerical Simulation ◽  
Sand Casting

scholarly journals Numerical Simulation of Brazing Aluminium Alloys with Al–Si Alloys

2018 ◽  
Vol 71 (11) ◽  
pp. 2623-2629 ◽  
Author(s):  
J. Lacaze ◽  
B. Jacques ◽  
T. Mazet ◽  
M. Vynnycky
Keyword(s):  
Numerical Simulation ◽  
Aluminium Alloys

Numerical Simulation of Sand Casting Process: A Case Study on Globe Valve

2020 ◽  
pp. 533-541
Author(s):  
Yash Mittal ◽  
Nikhil Parasar ◽  
Jambeswar Sahu ◽  
Umakant Mishra ◽  
Chinmaya P. Mohanty
Keyword(s):  
Numerical Simulation ◽  
Casting Process ◽  
Sand Casting ◽  
Globe Valve

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.

Influence of Friction Stir Welding Variants on Crashworthiness of Friction Stir Welded Aluminium Top Hat Sections

2020 ◽  
Vol 979 ◽  
pp. 97-101
Author(s):  
A.K. Lakshminarayanan ◽  
Cyril Joseph Daniel
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Aluminium Alloys ◽  
Static Loading ◽  
Welding Process ◽  
Frontal Crash ◽  
Friction Stir ◽  
Related Defect

The motivation for this research is the desire to design a cross-section of frontal crash absorbing member that deforms in a regular controlled manner, but also the desire for cost-to-weight effectiveness. Nowadays, Friction Stir Welding (FSW) is a popular process for welding of difficult to weld aluminium alloys due to its advantages of solidification related defect free microstructure, low residual stress and comparable mechanical properties with the base metal. In order to better understand the crashworthiness of aluminium alloy joints produced by FSW, this investigation was carried out to fabricate a frontal member top hat section with base member welded by three different friction stir welding process variants. The crashworthiness was investigated by subjecting the fabricated joints to quasi static loading and the results are reported. The experimental results are compared with the results of numerical simulation.

scholarly journals Feasibility of Calcium Sulfate Moulds Made by Inkjet 3D Printing for Rapid Casting of Aluminium Alloys

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 802 ◽  
Author(s):  
Pablo Rodríguez-González ◽  
Pablo Eduardo Robles Valero ◽  
Ana Isabel Fernández-Abia ◽  
María Ángeles Castro-Sastre ◽  
Joaquín Barreiro García
Keyword(s):  
3D Printing ◽  
Aluminium Alloys ◽  
Casting Process ◽  
Sand Casting ◽  
Filling Process ◽  
Critical Aspect ◽  
Dimensional Precision ◽  
Filling System ◽  
Staircase Effect ◽  
Design Freedom

In this research, a comparative analysis has been carried out between a traditional sand casting process and a modern mould obtained by additive manufacturing (AM), in the context of aluminium parts production. In this case of AM, an inkjet 3D printing (3DP) process allowed us to create a ceramic mould. A numerical simulation was carried out to study the filling and cooling rates of both parts. The design freedom typical of the 3DP technique allowed us to optimize the filling system. The results showed that in sand moulding, the speed in the gate suddenly increased when the liquid metal entered the part cavity, leading to severe turbulence due to the fountain effect. The input of air is related to the speed in the gate. Nevertheless, the results showed that when using the 3DP mould, the speed in the gate remained constant and the filling process was homogenous. With regard to the dimensional precision, while the staircase effect in the surface of the 3DP mould is the most critical aspect to control, in the sand casting mould the critical aspect is the dimensional precision of the pattern. Microstructures of the cross-section of the moulded parts showed folded shapes and air input in sand casting, which could be produced by the severe turbulence and the oxide film present in the melt during the filling process. On the other hand, the porosity found in parts produced with the 3DP mould corresponds to shrinkage; during the filling process, the remaining binder is vaporized, creating nucleation points. In this way, pores are formed by shrinkage and a mixture of shrinkage and gas entrapment. With these considerations, it can be concluded that AM shows feasibility and advantages as an alternative to the sand casting method for aluminium alloys.

Sign in / Sign up

Export Citation Format

Share Document