Process Optimization of Large Turbine Blade Casting Base on Numerical Simulation

2009 ◽  
Vol 16-19 ◽  
pp. 535-539
Author(s):  
Deng Yu Gai ◽  
Yu Zhao Chu ◽  
Qing Fen Li ◽  
Qun Xia Li
Keyword(s):  
Numerical Simulation ◽  
Velocity Field ◽  
Stress Field ◽  
Turbine Blade ◽  
Process Optimization ◽  
Temperature Fields ◽  
Solidification Processes ◽  
Velocity And Temperature Fields ◽  
Blade Casting ◽  
Filling And Solidification

3-D velocity and temperature fields of mold filling and solidification processes of large turbine blade casting were simulated. It indicated that the velocity field of upright casting is faster and steadier than lying casting. The deformation was predicted and the rule of deformation was reflected by analyzing stress field during solidification of upright casting. The casting processes were optimized, and then applied to produce castings.

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.

Numerical Simulation Software of Casting Process used for Computer Aided Instruction

2011 ◽  
Vol 399-401 ◽  
pp. 13-16
Author(s):  
Jian Min Zeng ◽  
Jie Liang ◽  
Zhi Liu Hu ◽  
Ping Chen ◽  
Li Hua Liang
Keyword(s):  
Numerical Simulation ◽  
Casting Process ◽  
Simulation Software ◽  
Computer Aided Instruction ◽  
Casting System ◽  
Computer Aided ◽  
Solidification Processes ◽  
Software Utility ◽  
Casting Design ◽  
Filling And Solidification

Simulation software is an essential tool for today‘s engineers. Its application enables castings to be designed with predicting the final results prior to they are produced. Thus, the simulation plays significant role in casting production. If a realistic calculation of the mold filling and solidification processes can be made it is possible to predict casting defects caused by casting system and/or casting design. In order to understand the changes occurring during solidification of casting, numerical simulation has been used in our classroom teachings for postgraduates. The software structures, mathematical principles, software utility, functions and output criteria are introduced in this paper to demonstrate that computer aided instruction is of Intuitive, attractive and can be used in classroom before the real experiments as assistant means to help postgraduates to understand what is casting and what is solidification

Numerical Simulation of the Coordination Between Velocity and Temperature Fields for Air Flow Across Staggered Elliptic Tube Bundles

2007 ◽  
Author(s):  
Yangjun Wang ◽  
Xianhe Deng ◽  
Debin Huang
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Heat Transfer Performance ◽  
Temperature Fields ◽  
Dimensionless Temperature ◽  
Dimensionless Velocity ◽  
Tube Bundles ◽  
Field Coordination ◽  
Velocity And Temperature Fields ◽  
Coordination Principle

The coordination between the velocity and temperature fields in 2-D developed turbulent flow is analyzed for air across the staggered elliptic tube bundles by means of numerical simulation. The results indicate that the convective heat transfer performance is dominated by the degree of coordination between the velocity and temperature fields. Furthermore, the included angle β between the dimensionless velocity and dimensionless temperature gradient vectors is one of the important factors to control the coordination. The field coordination can be improved by adjusting the include angle β, subsequently the heat transfer can be enhanced effectively. Field coordination principle promotes the development of heat transfer research in a controllable direction.

Simulation of Mold Filling and Solidification on Gravity Casting of Al-Si Alloy (A357)

2008 ◽  
Vol 575-578 ◽  
pp. 1204-1209
Author(s):  
Guo Fa Mi ◽  
Heng Tao Zhao ◽  
Kuang Fei Wang ◽  
Zhi An Xu ◽  
Ji Tai Niu
Keyword(s):  
Solidification Process ◽  
Mold Filling ◽  
Simulation Software ◽  
Temperature Fields ◽  
Al Alloy ◽  
Alloy Sample ◽  
Gravity Casting ◽  
Solidification Processes ◽  
Feeding Process ◽  
Filling And Solidification

The temperature at specific positions was measured by multi-channel data acquisition system in order to understand the solidification and feeding process of the sample. The Olympus metallurgical microscope was used to observe the macrostructure of the casting and analyze the freezing mechanism. The mold filling and solidification processes of the Al-alloy sample were studied by using the commercialized simulation software Z-Cast. And the simulated result was compared with the results of practical pouring test. When preheat temperature of mold is low, the pouring temperature should be higher in order to ensure completely filling of mold. As a result the solidification of sample could be feeding effectively, and the shrinkage on the upper end of sample could be eliminated. It is shown that the casting simulation software Z-CAST can be used to simulate the filling and solidification process of gravity cast Al alloy and can provide exact flow fields and temperature fields thus can predict cast defects and their positions.

Simulation of Thixocasting Processes in Automotive Component

2005 ◽  
Vol 480-481 ◽  
pp. 361-366
Author(s):  
Antonio Forn ◽  
Sergi Menargues ◽  
Enric Martín ◽  
G.L. Chiarmetta
Keyword(s):  
Experimental Data ◽  
Numerical Simulation ◽  
Structural Parameter ◽  
Homogeneous Material ◽  
Simulation Tools ◽  
Die Filling ◽  
Real Process ◽  
Solidification Processes ◽  
Semi Solid ◽  
Filling And Solidification

Thixocasting or semi-solid casting is an alternative to the traditional casting processes. A numerical simulation of these methods is useful to define the real process. A new test concept will be presented to determine parameters, such as temperature and rates, as well as the die filling and solidification processes. The simulation tools permit us to understand better the processes, to predict and to eliminate potential defects before they take place. The studied component is a steering knuckle made of an A357 aluminium alloy. The microstructure is characterized by optical microscopy. It has been preceded to the development of a model based on the experimental data, it has been defined to the semi-solid as an homogeneous material with thixotropic properties, and the microstructure is a structural parameter. The results are compared with real tests.

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