scholarly journals Defects Analysis Using E Foundry and Flow Simulation for Crank Case Casting

10.29007/xl1j ◽  
2018 ◽  
Author(s):  
Yogin Vekariya ◽  
Trushant Desai ◽  
Rakesh Barot ◽  
Balkrushna Sharma
Keyword(s):  
Molten Metal ◽  
Computer Technology ◽  
Metal Flow ◽  
Flow Analysis ◽  
Flow Characteristics ◽  
Flow Simulation ◽  
Casting Process ◽  
Gating System ◽  
Dross Formation ◽  
Defects Analysis

Casting process deals with the metal in the molten state. When the molten metal is poured into the mold box, Smooth and turbulence less flow with appropriate velocity is need to be ensured. Type of flow while pouring the molten metal has significant influence on the end characteristics of casting. Inefficient metal flow can result in error beyond altering the desired characteristics of casting. Dross formation while pouring the metal has direct connection with the type of flow of molten metal. In short, one cannot neglect the flow of molten metal on other hand expecting sound casting formation. Gating characteristics directly deals with the type of flow expected while pouring. To provide desired flow is one of the functions of efficient gating system. But it is very difficult to consider the flow characteristics while actually designing the gating system. Computer technology has taken leap to aid foundry engineer in control of metal flow. Simulation soft-wares have been equipped with provision of flow analysis while designing the Gating system.

Automatic Control of Molten Metal Flow for Improving Casting Performance

2011 ◽  
Vol 693 ◽  
pp. 179-184
Author(s):  
Thomas Jarlsmark ◽  
Jan Strömbeck ◽  
Mikael Terner ◽  
Jerry Wilkins
Keyword(s):  
Molten Metal ◽  
Metal Flow ◽  
Casting Process ◽  
Direct Chill ◽  
Level Control ◽  
Level Measurement ◽  
Cost Efficient ◽  
Molten Metal Flow ◽  
Automatic Level ◽  
Rolling Ingot

The ways to gain better quality and higher casting performance is an urgent topic among aluminium producers today. This issue is also often on the agenda at conferences like this and the subjects and technologies to achieve this varies. Controlling the molten metal flow by maintaining predefined levels or level patterns is one of many powerful tools to reach this goal. Precimeter Control specializes in applications for non-ferrous molten metal level measurement and molten metal flow control. By integration, or retrofitting, any new or existing casting line can easily be automatically controlled and gain improved casting performance in a cost efficient way. This paper will focus on the main benefits from automatic level control and how some plants have achieved improvements in their casting process of DC (Direct Chill) slab (or rolling ingot) casting after implementing such technology.

Flow Analysis of Spray Jet and Direct Jet Nozzle for Fire Water Monitor

2010 ◽  
Vol 139-141 ◽  
pp. 913-916 ◽  
Author(s):  
Guo Liang Hu ◽  
Wei Gang Chen ◽  
Zhi Gang Gao
Keyword(s):  
Flow Analysis ◽  
Flow Characteristics ◽  
Flow Simulation ◽  
Jet Flow ◽  
Extended Length ◽  
Jet Nozzle ◽  
Simulation Results ◽  
Steady Velocity ◽  
Nozzle Structure

In order to investigate the influence rules between the jet nozzle of fire water monitor and the jet performances, two typical jet nozzle, the spray jet and direct jet nozzle was designed to analysis the jet flow characteristics. Flow simulation of the jet nozzle was completed using fluent kits. The outlet velocity of the spray jet nozzle and direct jet nozzle were investigated in detail, and the influence rules of the nozzle structure on the outlet velocity was also discussed. The simulation results show that the steady velocity of the jet nozzle is about 34m/s that coinciding the contour magnitude, and the better extended length of the direct jet nozzle is about 50mm length that can improve the jet performances. The results can verify the reasonableness of the designed nozzle, it also can optimize the nozzle structure and increase the jet performance of the fire water monitor.

Influence of Casting Speed on Temperature and Flow Fields in Molten Pool during Twin-Roll Strip Casting Process

2006 ◽  
Vol 505-507 ◽  
pp. 1315-0
Author(s):  
Xiao Ming Zhang ◽  
Zheng Yi Jiang ◽  
Xiang Hua Liu ◽  
Guo Dong Wang ◽  
L.M. Yang ◽  
...  
Keyword(s):  
Casting Speed ◽  
Molten Pool ◽  
Metal Flow ◽  
Flow Analysis ◽  
Casting Process ◽  
Strip Casting ◽  
The Stability ◽  
Twin Roll ◽  
Temperature And Flow Fields

In twin-roll strip casting process, the casting speed has a significant influence on the metal flow and temperature distribution in the molten pool, which will affect the stability of this process and the quality of the produced products. Based on a 3D coupled thermal-flow analysis, a combination of the experimental results for twin-roll strip casting of stainless steel, heat equilibrium calculation and simulation results was conducted, and the boundary conditions of the heat exchange between the rolls and molten pool has been treated effectively. The effect of the casting speed on the flow and temperature in the molten pool was given. Simulation result is in agreement with the measured value.

A Network Technique for Metal Flow Analysis in the Filling System of Pressure Diecasting and its Experimental Verification on a Cold Chamber Machine

1992 ◽  
Vol 206 (4) ◽  
pp. 261-275 ◽  
Author(s):  
S B Sulaiman ◽  
D T Gethin
Keyword(s):  
Stokes Equations ◽  
Metal Flow ◽  
Flow Analysis ◽  
Flow Characteristics ◽  
Navier Stokes ◽  
Navier Stokes Equations ◽  
Part Type ◽  
Filling System ◽  
Cold Chamber ◽  
Actual Part

This study reports the results of analysis and measurement of metal flow in the pressure diecasting process. The analysis involved the simplification of the Navier Stokes equations and solution of the resulting set using a network method. Since the filling system is an important part of the pressure diecasting process, this aspect was, studied. Concurrently, an experiment to measure pressure in the diecasting process was carried out on a cold chamber machine to obtain the pressure history and flow characteristics. The predicted results were then compared with experimental data and agreement between them was achieved. In addition the fill of an actual part type has been carried out to illustrate the modelling capability.

The Effect of Vortex well Thickness on Microstructure and Mechanical Properties of Aluminium LM6

2013 ◽  
Vol 465-466 ◽  
pp. 1219-1223
Author(s):  
H. Hehsan ◽  
Roslee Ahmad
Keyword(s):  
Mechanical Properties ◽  
Temperature Distribution ◽  
Flexural Strength ◽  
Metal Flow ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Casting Defects ◽  
Gating System ◽  
Cast Material ◽  
Microstructure And Mechanical Properties

Gating system in a casting mold consists of a series of channels and reservoirs designed to feed molten metal to all parts of the mold cavity. The design of the system is the principle means by which the mold designer can control the rate of the metal flow and promote the desirable temperature distribution of cooling that will take place within the filled cavity. This research was conducted to determine the effects of vortex well thickness on the microstructure and mechanical properties of Aluminium LM6 in sand casting process. The experimental results show that increasing the vortex well thickness leads to a significance improvement on the flexural strength of the cast material. In addition, casting defects such as shrinkage porosity and gas porosity would be minimized as the thickness of the vortex well increases.

Flow Analysis of a Shrouded Aerosol Sampling Inlet

2013 ◽  
Vol 347-350 ◽  
pp. 3903-3906
Author(s):  
Bao Qing Wang ◽  
Shu Yao ◽  
De Qing Wang ◽  
Zhi Peng Bai ◽  
Xin Hua Wang
Keyword(s):  
High Speed ◽  
Cfd Simulation ◽  
Flow Analysis ◽  
Flow Characteristics ◽  
Flow Simulation ◽  
Aerosol Sampling

A shrouded aerosol sampling inlet has been designed from high-speed aircraft. The sampling inlet was conducted using the CFD to perform a flow simulation. The shroud diameter is 150 mm. The inlet is located 180mm from the shroud entrance plane. The shroud is 300 mm long. Results are presented graphically, showing the shrouds have provided significant improvements in flow characteristics. Straighten the streamlines of gas of sampling inlet for flow angles up to five degrees. It is suggested that CFD simulation can be useful for improving the optimum a shrouded aerosol sampling inlet.

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