Study of Pre-Processing Technology for Zinc Alloy Die-Casting Numerical Simulation on Flow-3D

2012 ◽  
Vol 184-185 ◽  
pp. 1232-1235
Author(s):  
Jiang Nan Shen ◽  
Liu Lang Lai ◽  
Yan Ping Li
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Simulation Software ◽  
Zinc Alloy ◽  
Efficient Tool ◽  
Parameters Selection ◽  
And Function ◽  
3D Software ◽  
And Control ◽  
Selection Of

The technologies of computer numerical simulations on casting process has penetrated into the every field of shape process, and offer a efficient tool for casting technological design. The paper briefly introduces the characteristics of the Flow-3d software on the principle and function, which is superior to that of other casting simulation software. Then, many die casting casts have been modeled and simulated, focus on the content of Pre-processing, summed up the major principles and skills on STL Import, Mesh Building and Control parameters selection of Flow-3D software by using the means of analogy.

Fatigue Life Prediction in Rapid Die Casting

2008 ◽  
Author(s):  
Chuan Huat Ng ◽  
Karl-Heinrich Grote ◽  
Ru¨diger Ba¨hr
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Fatigue Life ◽  
Experimental Testing ◽  
Die Casting ◽  
Life Time ◽  
Casting Process ◽  
Simulation Software ◽  
Stress Strain ◽  
Fracture Models

During a die casting process, it is very difficult to achieve efficient and correct casting tooling endurance results by the casting designer and foundry man. However, it is very costly and time consuming to predict the tooling endurance with a trial and error method based on expertise and experience. After an extensive fatigue design study, it was possible to develop specimen design models for the simulation of the time and temperature dependent stress-strain and fracture models to determine the thermal fatigue prediction. In this research, stress-strain approach, heat transfer concept and life time calculation methods were used to predict the casting tool endurance by a computer simulation. The thermal stress and heat transfer behaviour analysis were performed using RWP casting numerical simulation software. It is shown that numerical simulation techniques can simulate stress concentration on the specimen surface to thermal behaviour. Furthermore, the result from the specimen based simulation model associated with fracture indicators permits the construction of a life time design curve independent of time and temperature. The fatigue life predicted by simulation based models and the results from experimental testing on real components are very similar. The simulation results showed that they match the experimental results, including a design safety factor.

Simulation of High Pressure Die Casting Solidification

2006 ◽  
Vol 508 ◽  
pp. 555-560 ◽  
Author(s):  
Dániel Molnár ◽  
Jenő Dúl ◽  
Richárd Szabó
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
High Pressure Die Casting ◽  
Die Casting Process ◽  
The University ◽  
Pressure Die Casting

By the help of simulation software it is possible to follow and predict the high pressure die casting process. In the Department of Foundry Engineering at the University of Miskolc, Hungary we use both Finite Element- and Finite Difference programs for simulation. In this paper we examine a special specimen, a plate with knobs, witch has point symmetric hot spots and cored parts which effect the characteristic of flow and solidification. We examined the solidification process and the temperature distribution. We determined that the finite element method, because of the meshing and the calculation mode, is more suitable for the simulation of thermal processes.

Numerical Study on the Low Pressure Die Casting of AZ91D Wheel Hub

2005 ◽  
Vol 488-489 ◽  
pp. 393-396 ◽  
Author(s):  
Ying Hong Peng ◽  
Da Yong Li ◽  
Ying Chun Wang ◽  
Ji Long Yin ◽  
Xiao Qing Zeng
Keyword(s):  
Cooling System ◽  
Numerical Study ◽  
Liquid Fraction ◽  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Cooling Capacity ◽  
Simulation Software ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

Most magnesium alloy components available for automobile are made through die casting. In this paper, PAM-CASTTM, commercial die casting simulation software based on the finite difference method, is employed to simulate the low-pressure die casting process of magnesium wheel hub. The temperature field and velocity field during filling and solidification stages are analyzed; the evolution of temperature distribution and liquid fraction was numerically studied. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes are predicted. The cooling performance of mould during casting is also investigated. Via analyzing the shrinkage defects generated under various cooling conditions, the cooling system set in the side mould is found to be more effective for enhancing the cooling capacity at the rim/spoke junction areas. With this cooling system, the hot spots at the junctions are obviously reduced and product quality is improved.

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.

Aluminum Casting Processes

2004 ◽  
pp. 21-37
Keyword(s):  
Metal Matrix ◽  
Historical Development ◽  
Die Casting ◽  
Hot Isostatic Pressing ◽  
Casting Process ◽  
Matrix Composites ◽  
Metallurgical Bonding ◽  
Alloy Castings ◽  
Pressure Die Casting ◽  
Selection Of

Abstract This chapter begins with information on the historical development of aluminum alloy castings. It then covers the basic factors involved in the selection of a casting process. This is followed by sections describing the various categories of casting processes and their variants: expendable mold gravity-feed casting, nonexpendable (permanent) mold gravity feed casting, and pressure die casting. Next, the chapter describes the technologies used to produce premium engineered castings and when such castings may be relevant. The chapter concludes with descriptions of other process technologies used with castings, including metallurgical bonding, metal-matrix composites, and hot isostatic pressing.

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.

Numerical Simulation of the Car Oil Pump Support Die Casting

2013 ◽  
Vol 753-755 ◽  
pp. 908-912
Author(s):  
Ran Wei ◽  
Yong Su ◽  
Yun Ji Zhang
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Solidification Shrinkage ◽  
Oil Pump ◽  
Mould Filling ◽  
Filling And Solidification ◽  
Casting Simulation Software

In this paper, the die-casting processing of aluminum alloy was simulated by casting simulation software. The mould filling and solidification process of aluminum alloy die-casting in different cast temperature and shot velocity were investigated. Aiming at achieving the best casting process, this research gave emphasis on analysis the influence of cast temperature and shot velocity to the process of mould filling, temperature field of casting part during filling and solidification, shrinkage and porosity. To improve the process, increase ingate area, carry on the simulation, and analyze the optimal casting parameters.

Study on Die Casting Simulation for Magnesium Alloy Cylinder Cover Based on JSCAST

2014 ◽  
Vol 800-801 ◽  
pp. 847-851
Author(s):  
Qing Ming Hu ◽  
Shi Gang Wang ◽  
Dong Sheng Li ◽  
Jian Hua Guo ◽  
Cheng Xu
Keyword(s):  
Magnesium Alloy ◽  
Production Efficiency ◽  
Simulation Analysis ◽  
Die Casting ◽  
Casting Process ◽  
Simulation Software ◽  
Casting Simulation ◽  
Filling Process ◽  
Automotive Engine ◽  
Die Casting Process

Magnesium alloy has widely been used in automotive sector due to its light weight, low density, high stiffness, and excellent casting performance and easy to recover and utilize. The magnesium alloy automotive engine cylinder cover was chosen as researching object to simulate its die casting filling process based on die casting filling process theory and numerical simulation analysis software JSCAST. The simulation results show that the utilization of die-casting simulation software for improving product quality and production efficiency has certain significance during the production of magnesium alloy die casting process.

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