scholarly journals Al-Si and Al-Si-Mg Cast Alloys Shrinkage Porosity Estimation

2016 ◽  
Vol 16 (1) ◽  
pp. 61-68 ◽  
Author(s):  
S. Samavedam ◽  
S. Sundarrajan
Keyword(s):  
Process Simulation ◽  
Three Dimensional ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Three Dimensional Model ◽  
Cast Alloys ◽  
And Control ◽  
Shrinkage Characteristic ◽  
Casting Process Simulation

Abstract US A356 and US 413 cast aluminium alloys shrinkage characteristic have been discussed in the present study. Specific volume reduction leads to shrinkage in castings and it can be envisaged as a casting defect. Finite difference based casting process simulation software has been used to study the shrinkage characteristic and it is quantified using mathematical formulae. The three dimensional model of the shrinkage defect has been constructed using CAD application software. Shrinkage characteristic has also been quantified through experimental validation studies and compared well with casting process simulation. Shrinkage characteristic study and control is essential for producing defect free castings. Influence of casting shape on the shrinkage characteristic has been studied in this paper.

Application of Numerical Simulation on Cast-Steel Axle’s V-Method Foundry

2010 ◽  
Vol 139-141 ◽  
pp. 576-579
Author(s):  
Guo Fa Mi ◽  
Li Lin Chen ◽  
Hong Yan Nan
Keyword(s):  
Numerical Simulation ◽  
Cast Steel ◽  
Three Dimensional ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Three Dimensional Model ◽  
Original Process ◽  
Shrinkage Defects ◽  
Improved Technology

The V-method foundry is an advanced casting technology compared with traditional sand casting. The Pro/E software was used to generate three-dimensional model of cast parts. The solidification process of the automotive axle casting with V-method foundry was simulated by the numerical simulation software, ViewCast. The location and scale of the shrinkage defects caused by the original process were predicted. According to the simulation results, the position of the flange round cooled too fast, which blocked the feeding passage of the round near sprue. The reason was that solidifying sequence was unperfected. The casting process was optimized by means of adding runner and chill. Progressive solidification can be obtained and the shrinkage defects can be eliminated or transferred by the improved technology. The reasonable casting process was obtained and the process has been proofed by the productive practice.

Defect Free Casting by Using Simulation Software

2013 ◽  
Vol 313-314 ◽  
pp. 1130-1134 ◽  
Author(s):  
C.M. Choudhari ◽  
K.J. Padalkar ◽  
K.K. Dhumal ◽  
B.E. Narkhede ◽  
S.K. Mahajan
Keyword(s):  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Cast Aluminum ◽  
Industrial Case Study ◽  
Aluminum Castings ◽  
Mould Filling ◽  
Improved Performance ◽  
And Control

The use of Aluminum castings parts in the automotive industry has increased dramatically over the past few decades. The driving force for this increased use is vehicle weight reduction for improved performance. In many cases the mechanical properties of the cast aluminum parts are superior to those of the cast iron or wrought steel parts being used.This paper proposes the computer simulation of the sand casting of Aluminum Plate. It aims to study the behavior of fluid flow during mould filling and solidification and to optimize the process parameters, which help to predict and control casting defects such as gas porosity and shrinkage porosity. Here an attempt is being made to model and simulate the casting process using the AutoCAST software. The technological as well as practical aspects of using casting software are illustrated with an industrial case study.

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.

Numerical Simulation on the Liquid Metal Flow of the Acceleration Phase in the Shot Sleeve of Cold Chamber Die Casting Process

2007 ◽  
Vol 561-565 ◽  
pp. 1801-1804
Author(s):  
Jie Yang ◽  
Lang Yuan ◽  
Shou Mei Xiong ◽  
Bai Cheng Liu
Keyword(s):  
Numerical Simulation ◽  
Liquid Metal ◽  
Metal Flow ◽  
Three Dimensional ◽  
Great Influence ◽  
Casting Process ◽  
Shot Sleeve ◽  
Three Dimensional Model ◽  
Acceleration Phase ◽  
Fill Ratio

Slow shot velocity and its acceleration phase in the shot sleeve have great influence on the flow pattern of the liquid metal in the shot sleeve. In this paper, a three-dimensional model based on the SOLA-VOF algorithm was developed and used to simulate the flow of melt in the shot sleeve. The mathematical model was verified by water analog experiments with constant plunger velocities. Based on numerical simulation results, the influences of the plunger acceleration on the wave profile of the liquid metal in the shot sleeve under different fill ratios and sleeve diameters were investigated. The results indicated that in order to avoid air entrapment in the shot sleeve, the optimal acceleration value to the critical slow shot velocity increases with the increase of the fill ratio, and the range of suitable acceleration becomes wider as well. With the same fill ratio, the value of suitable acceleration rises as the plunger diameter increases.

The Parametric Analysis of the Threshold Value Judging Mechanism in MEMS Safety and Arming Device

2015 ◽  
Vol 645-646 ◽  
pp. 968-971
Author(s):  
Fu Fu Wang ◽  
Wen Zhong Lou ◽  
Fang Yi Liu ◽  
Da Kui Wang ◽  
Ming Rong Zhang ◽  
...  
Keyword(s):  
Three Dimensional ◽  
Threshold Value ◽  
Element Model ◽  
Dimensional Model ◽  
Three Dimensional Model ◽  
Long Distance ◽  
And Control ◽  
The Mathematical Model ◽  
The Finite Element Model

In this paper, a mechanical MEMS S&A device has been proposed. The size of the device is 10mm×13mm×0.5mm. The role of the threshold value judging mechanism is to determine the environment suffered by centrifugal force and control the sub-centrifugal slider not movement under the threshold, so as to effectively guarantee the time of long-distance arming. Through establishing the three-dimensional model of threshold value judging mechanism, establishing the force and the parameters of locking-releasing mechanism, deriving the mathematical model according to the rigid dynamic mechanics theory and establishing the finite element model by using ANSYS/LS-DYNA, appropriate threshold value judging mechanism is designed to meet two items, one item is the deformation of threshold value rod is not enough to release sub-centrifugal slider when the speed is less than 60000r/min; the other item is deformation of threshold value rod can release sub-centrifugal slider when the speed is more than 60000r/min.

The History of Casting Process Simulation

Shape Casting ◽  
2011 ◽  
pp. 1-12
Author(s):  
Christof Heisser ◽  
Erwin Flender ◽  
Jörg C. Sturm
Keyword(s):  
Process Simulation ◽  
Casting Process ◽  
History Of ◽  
Casting Process Simulation

Dynamic Simulation and Control Strategy of Centrifugal Flying Shear

2009 ◽  
Vol 16-19 ◽  
pp. 278-282
Author(s):  
Jin Chun Song ◽  
Chang Zhou Wang ◽  
Dong Xu
Keyword(s):  
Dynamic Simulation ◽  
Control Strategy ◽  
Optimization Design ◽  
Three Dimensional ◽  
Three Dimensional Model ◽  
Production Lines ◽  
Electronic Control System ◽  
Working Principle ◽  
Parameter Optimization Design ◽  
And Control

Centrifugal Flying Shear is one of the most advanced equipments, which is widely used in tandem mill production lines because of its simple structure and high shearing precision. In this paper, the working principle of the centrifugal flying shear was introduced; the three-dimensional model of the centrifugal flying shear was established; the structural analysis and the dynamic simulation of the flying shear, with the movement rule and trajectory, were made based on MATLAB/SimMechanics and Solidworks/COSMOS Motion; and the control strategy of realizing scale shearing was proposed. The results obtained provide theoretical basis for design of the electronic control system, and facilitate further analysis of the shearing process and parameter optimization design of similar flying shears.

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