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.

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.

Modeling Analysis and Optimization of Sand Casting Process

2012 ◽  
Vol 479-481 ◽  
pp. 226-229
Author(s):  
Qing Ming Chang ◽  
Jing Yuan ◽  
Yin Kai Yang ◽  
Xia Chen
Keyword(s):  
Casting Process ◽  
Two Dimensions ◽  
Sand Casting ◽  
Shrinkage Cavity ◽  
Uniform Mesh ◽  
Pouring Temperature ◽  
Cover Type ◽  
Modeling Analysis ◽  
Uniform Wall ◽  
Simulation Results

In this research paper, the sand casting process of a cover-type part for wind turbine was investigated with ProCAST software . The cover-type casting part is big in two dimensions and it is heavy in some local positions where shrinkage cavity and porosity are very likely to from. A non-uniform mesh is used corresponding to the non-uniform wall thickness. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results 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

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.

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.

Numerical simulation of the casting process of a wind turbine rotor hub

Wind Energy ◽  
2010 ◽  
Vol 13 (8) ◽  
pp. 727-736
Author(s):  
Chun-Ping Yeh ◽  
Weng-Sing Hwang
Keyword(s):  
Numerical Simulation ◽  
Wind Turbine ◽  
Casting Process ◽  
Turbine Rotor ◽  
Wind Turbine Rotor

Study on the Causes and Prevention Measures of Shrinkage Defects of Heavy V-Belt Pulley in the Production

2014 ◽  
Vol 722 ◽  
pp. 231-234
Author(s):  
Gui Qin Jin ◽  
Tao Yan ◽  
Cui Feng Chen
Keyword(s):  
Chemical Composition ◽  
Hot Spot ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Shrinkage Cavity ◽  
Optimized Design ◽  
Prevention Measures ◽  
Pouring Temperature ◽  
Performance Requirements ◽  
Shrinkage Defects

Shrinkage cavity and shrinkage porosity, often occurring during the production of heavy v-belt pulley roughcast, may lead to the decrease of the pulley performance and further result in casting rejection. Therefore, it is necessary to study the causes and prevention measures of shrinkage defects of the casting. The material of V-belt pulley roughcast at issue is HT250 and it adopts resin sand casting process. With a large amount of practice in workshop and times of revision of the design of foundry technology, we have found that the shrinkage in the hot spot of heavy v-belt pulley roughcast can be reduced or even eliminated to fully meet the performance requirements with a moderate control of pouring temperature and speed, an optimized design of foundry technology, and a strict limitation of chemical composition. This finding will bring illumination to the production process of other heavy pulley roughcast.

Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting

2011 ◽  
Vol 121-126 ◽  
pp. 254-258
Author(s):  
Bai Yang Lou ◽  
Fang Li Liu ◽  
Kang Chun Luo
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Casting Defects ◽  
Casting Simulation ◽  
Pressure Die Casting ◽  
Filling And Solidification

The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

The Numerical Simulation about Second Dendrite Spacing of Low Pressure Casting Automobile Aluminum Magnesium Alloy Wheel

2011 ◽  
Vol 189-193 ◽  
pp. 2096-2102 ◽  
Author(s):  
Xin Zhao ◽  
Yan Wei Sui ◽  
Ai Hui Liu ◽  
Fei Fei Wang ◽  
Zhi Sun ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Cooling Water ◽  
Casting Process ◽  
Low Pressure ◽  
Pressure Casting ◽  
Pouring Temperature ◽  
Alloy Wheel ◽  
Preheating Temperature ◽  
Low Pressure Casting ◽  
Cooling Pipes

Using the method of numerical simulation and the AnyCasting software, the simulation for SDAS of Al-Mg alloy wheels for low pressure casting is studied. The simulation model is established and the effects of preheating temperature, melt pouring temperature and cooling water pipes on SDAS in the low pressure casting process was founded. The results show that, SDAS presents linear variation with the increase of preheating temperature and pouring temperature; opened cooling pipes make SDAS smaller. The practice of simulating casting is verified by experiments, and test results and simulation results were consistent.

Numerical Simulation Analysis of Aluminium Alloy Wheels Casting Defects and Casting Process Optimization

2013 ◽  
Vol 749 ◽  
pp. 125-132 ◽  
Author(s):  
Lv Ming Yang ◽  
Li Li Zhao ◽  
Qing Qing Zhang ◽  
Tie Tao Zhou
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Casting Process ◽  
Shrinkage Cavity ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Casting Defects ◽  
Pressure Casting ◽  
Aluminum Alloy Casting

In the low pressure casting process of A356 aluminum alloy wheel hub, casting defects including shrinkage cavity, shrinkage porosity, impurity and pore usually occur inside the casting. These defects affect the mechanical properties of the casting. To solve this problem, we conducted a study based on a cooperation project with a well-known domestic automobile wheel manufacturer. In the present study, uniaxial tensile test of aluminum alloy casting containing defects was simulated and analysed, and the effect of types and number of defects on mechanical properties was studied by finite element analysis software. Statistical analysis of the data was provided by the manufacturer. It has been found that the degassing technology is effective by the quantitative analysis method. Based on the analyses of experimental data and the numerical simulation it is deduced that the tensile strength of casting increases with the increase of the defects due to the presence of impurity. This was confirmed in this research project, it has been observed that the defect rate of the casting sample is reduced from 5%-6% to less than 1%.

The Defects Analysis and Numerical Simulation of Automobile Brake Hydro Cylinder in Permanent Casting

2011 ◽  
Vol 704-705 ◽  
pp. 82-87
Author(s):  
Lei Rao ◽  
Lian Bing Zhu ◽  
Xiao Long Li ◽  
Qi Yao Hu
Keyword(s):  
Numerical Simulation ◽  
Shrinkage Cavity ◽  
Work Piece ◽  
Braking System ◽  
Casting Quality ◽  
Solidification Processes ◽  
Gas Entrapment ◽  
Defects Analysis ◽  
Filling And Solidification ◽  
Advanced Computer

Brake hydro cylinder is the key part of automobile hydraulic braking system, which usually works under high pressure condition. So, high safety factor of it is required to avoid accident. There are many kinds of casting defects such as shrinkage cavity, gas entrapment and slag enclosure are formed in the mold filling and solidification processes, which contribute to final casting performance. Based on the mathematical models of molding filling and solidification processes, the numerical simulation has been done. In the meanwhile, the defects forming reasons have been analyzed. According to the simulation results, two types of improved schemes have been analyzed and practiced respectively, and its work piece defects were reduced largely. It is an effective way to improve the casting quality by advanced computer technology.

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