Design of LPDC Process for Thin-Walled Casting Based on Numerical Simulation

2012 ◽  
Vol 217-219 ◽  
pp. 1786-1790
Author(s):  
Li Qiang Zhang ◽  
Rong Ji Wang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Boundary Conditions ◽  
Process Parameters ◽  
Casting Process ◽  
Manufacturing Cost ◽  
Simulation Technology ◽  
Thermal Boundary Conditions ◽  
Thin Walled

The LPDC process parameters of A356 thin-walled aluminum alloy were designed based on numerical simulation by precisely setting the thermal boundary conditions. By applying the designed process parameters, a sound casting with 300mm in length, 100mm in width and 1.5mm in thickness was successfully prepared. The results indicate the numerical simulation technology is an effective tool for designing casting process and reducing the manufacturing cost.

Numerical Simulation of LPDC Process for Thin-Walled Aluminum Alloy

2012 ◽  
Vol 538-541 ◽  
pp. 474-478
Author(s):  
Li Qiang Zhang ◽  
Rong Ji Wang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Manufacturing Cost ◽  
Casting Quality ◽  
Filling Ability ◽  
Low Pressure Die Casting ◽  
Thin Walled ◽  
The Cost ◽  
Pressure Die Casting ◽  
Selection Of

In general, the thin-walled casting with the thickness less than 2mm is not easy to be prepared using low-pressure die casting (LPDC) technology because of its poor filling-ability. In this paper, the LPDC process of A356 thin-walled aluminum alloy was simulated based on the selection of appropriate boundary conditions in order to save the cost. The simulation results compared with experimental results indicate the numerical simulation technology is an effective tool for reducing the manufacturing cost and improving the casting quality.

Numerical Simulation Research on Springback Controlling Methods of Aluminum Alloy Panel during Hydroforming

2016 ◽  
Vol 851 ◽  
pp. 163-167
Author(s):  
Dong Yan Lin ◽  
Yi Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Blank Holder Force ◽  
Scoring Method ◽  
Simulation Research ◽  
Blank Holder ◽  
Hydroforming Process

The hydroforming process of the aluminum alloy panel was simulated by the software DYNAFORM. The effects of process parameters (blank holder force, depth of panel and height of draw bead) on springback of the aluminum alloy were investigated. The max springback of the panel was analyzed by weighted scoring method. Then the process parameters were synthetically optimized for the max positive and negative springback. The results showed that the height of draw bead affects obviously the comprehensive springback of the panel. The optimization of the process parameters obtained by the orthogonal experiment can effectively reduce the max springback of the panel.

Optimization for Stamping Process Parameters of Front Fender Based on Numerical Simulation Technology

2010 ◽  
Vol 102-104 ◽  
pp. 232-236 ◽  
Author(s):  
Zhi Feng Liu ◽  
Qi Zhang ◽  
Wen Tong Yang ◽  
Jian Hua Wang ◽  
Yong Sheng Zhao
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Simulation Analysis ◽  
Explicit Method ◽  
Simulation Technology ◽  
Stamping Process ◽  
Automotive Panel

According to the characteristic which is more and difficult to determine about the automotive panel forming factors, based on the dynamic explicit method, taking the typical automobile front fender for example, do the simulation analysis by using of DYNAFORM. On the premise of taking springback factors into account, analog the best stamping process parameters has been optimized from the analysis results after simulation such as sheet metal forming limited drawing(FLD)and sheet metal thinning drawing.

Numerical Simulation of Casting Deformation and Stress of A356 Aluminum Alloy Thin-Walled Frame Casting

2021 ◽  
Vol 1033 ◽  
pp. 24-30
Author(s):  
Yi Dan Zeng ◽  
Li Tong He ◽  
Jin Zhang
Keyword(s):  
Aluminum Alloy ◽  
Casting Process ◽  
Mold Temperature ◽  
Hot Cracking ◽  
Thin Wall ◽  
A356 Aluminum Alloy ◽  
Pouring Temperature ◽  
Thin Walled ◽  
Alloy Castings ◽  
A356 Aluminum

One of the main reasons for the scrap of cast thin-wall frame aluminum alloy castings is deformation and cracking. It is an effective method for solving the problem by predicting the distribution of casting stress, clarifying the size of the deformation and the location of the crack, and taking necessary measures in the process. This paper uses the ProCAST software to simulate the thermal stress coupling of A356 thin-walled frame castings, analyzes the influence of pouring temperature, pouring speed and mold temperature on the stress field distribution of castings, predicts the hot cracking trend and deformation, and optimizes Casting process..

Study on the Forming Process of the Crossmember in Car Intermediate Floor

2013 ◽  
Vol 442 ◽  
pp. 593-598
Author(s):  
Xue Xia Wang ◽  
Peng Chong Guan ◽  
Hai Peng Li ◽  
Li Hui Wang ◽  
Na Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Simulation Results

Flanging and bending forming processes of the crossmember in car intermediate floor are investigated respectively by using numerical simulation technology. The numerical model of the crossmember was established and its press forming effect was simulated to determine the feasible process parameters affecting its manufacturability. Forming limit diagram and thickness distribution diagram are used to evaluate simulation results of different process schemes. And then optimum values of process parameters for flanging and bending are found, which can reduce the tendencies of wrinkling, springback and crackling during the stamping of the product.

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%.

scholarly journals Numerical simulation of natural convection in an inclined porous cavity under time-periodic boundary conditions with a partially active thermal side wall

RSC Advances ◽  
2017 ◽  
Vol 7 (28) ◽  
pp. 17519-17530 ◽  
Author(s):  
Feng Wu ◽  
Gang Wang
Keyword(s):  
Numerical Simulation ◽  
Natural Convection ◽  
Boundary Conditions ◽  
Periodic Boundary ◽  
Side Wall ◽  
Periodic Boundary Conditions ◽  
Porous Cavity ◽  
Thermal Boundary Conditions ◽  
The Right ◽  
Time Periodic

Natural convection in an inclined porous cavity with positively or negatively inclined angles is studied numerically for time-periodic boundary conditions on the left side wall and partially active thermal boundary conditions on the right wall.

Investigation on Forming Process of Automobile Trunk Side Panel Based on Numerical Simulation Technology

2013 ◽  
Vol 634-638 ◽  
pp. 2855-2860
Author(s):  
Hai Peng Li ◽  
Jia Wei Fan ◽  
Li Hui Wang ◽  
Xue Xia Wang ◽  
Ju Yuan Zhao
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Side Panel ◽  
Design Cycle

The forming process of automobile trunk side panel was investigated, using numerical simulation technology, to acquire the feasible process parameters and improve the formability of the product. With the technology, the manufacturability working procedures and drawing process parameters of the product were analyzed, calculated and simulated to achieve optimum formability characteristics. The method effectively lowers the probability of springback, wrinkling and thickness reduction, and shortens design cycle and cost. Based on the simulation results including forming limit diagram and thickness distribution diagram, the feasible process parameters are determined.

Computer Simulation of Low Pressure Casting Process Using Flow 3DTM

2015 ◽  
Vol 830-831 ◽  
pp. 45-48
Author(s):  
Abhilash Viswanath ◽  
Savithri Sivaraman ◽  
Uma Thanu Subramonia Pillai
Keyword(s):  
Numerical Simulation ◽  
Computer Simulation ◽  
Casting Process ◽  
Low Pressure ◽  
Processing Parameters ◽  
Pressure Casting ◽  
Mould Filling ◽  
Thin Walled ◽  
Low Pressure Casting ◽  
Filling And Solidification

The calibre of low pressure casting (LPC) process in meeting the demands for improved quality and aesthetics for thin walled components has been widely accepted in casting industries. In spite of numerous advantages, the process is still being used very less to its potential. The basic reason has been the difficulty in determining various processing parameters associated which can be circumvented effectively by numerical simulation. In the present work, the commercial CFD code FLOW 3DTM, has been used to simulate the mould filling and solidification during the LPC process.

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