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.

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.

Casting Process Solutions Optimization of LFC Forklift Box

2014 ◽  
Vol 571-572 ◽  
pp. 1091-1096
Author(s):  
Guang Sheng Zhang ◽  
Fei Zhang
Keyword(s):  
Orthogonal Experiment ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Technology Program ◽  
Original Process ◽  
Porosity Defects ◽  
Process Solutions ◽  
Technology Solution ◽  
Casting Simulation Software

There are many advantages in producing forklift box through the LFC. However, we found shrinkage porosity defects in the interior of castings through simulating the original process by ProCAST casting simulation software. Therefore, we analyzed the defects and improved the technology program. firstly, increased riser in position of shrinkage, Secondly, changed the filling’s way, lastly, selected the best temperature and vacuum by the orthogonal experiment and determined the best technology solution. we found the shrinkage porosity defects have been removed by the improved process. We found the production consistent with the simulation results through verification. Therefore we verify the accuracy of the ProCAST.

scholarly journals A Modular Digital Twinning Framework for Safety Assurance of Collaborative Robotics

2021 ◽  
Vol 8 ◽  
Author(s):  
J.A. Douthwaite ◽  
B. Lesage ◽  
M. Gleirscher ◽  
R. Calinescu ◽  
J. M. Aitken ◽  
...  
Keyword(s):  
Testing Strategy ◽  
Modular Architecture ◽  
Industrial Case Study ◽  
Safety Assurance ◽  
Physical Environments ◽  
Digital Twins ◽  
The Creation ◽  
Hardware Platforms ◽  
And Control

Digital twins offer a unique opportunity to design, test, deploy, monitor, and control real-world robotic processes. In this paper we present a novel, modular digital twinning framework developed for the investigation of safety within collaborative robotic manufacturing processes. The modular architecture supports scalable representations of user-defined cyber-physical environments, and tools for safety analysis and control. This versatile research tool facilitates the creation of mixed environments of Digital Models, Digital Shadows, and Digital Twins, whilst standardising communication and physical system representation across different hardware platforms. The framework is demonstrated as applied to an industrial case-study focused on the safety assurance of a collaborative robotic manufacturing process. We describe the creation of a digital twin scenario, consisting of individual digital twins of entities in the manufacturing case study, and the application of a synthesised safety controller from our wider work. We show how the framework is able to provide adequate evidence to virtually assess safety claims made against the safety controller using a supporting validation module and testing strategy. The implementation, evidence and safety investigation is presented and discussed, raising exciting possibilities for the use of digital twins in robotic safety assurance.

A Feasibility Report on the Comparsion of the Characteristics of Manufacturing a Bearing Cover by the Processes of Sand Casting and Shell Moulding

2018 ◽  
Vol 1148 ◽  
pp. 204-210
Author(s):  
M.Madhu Vamsi ◽  
V. Pradeep Kumar ◽  
S.H. Shariff
Keyword(s):  
Automotive Industry ◽  
Driving Force ◽  
Fuel Efficiency ◽  
Cast Aluminum ◽  
The Past ◽  
Casting Alloys ◽  
Aluminum Castings ◽  
Cast Alloys ◽  
Improved Performance ◽  
Cast Microstructure

The use of aluminum castings in the automotive industry has increased dramatically over the past two decades. The Al-Si system forms the basis of many important casting alloys, LM 0, LM 2, LM 4, LM 5, LM 6, LM 12, LM 13, LM 24 and LM 26 are the major cast alloys used in aerospace casting (e.g., fuel pump connectors) and premium automotive castings (e.g., suspension arms). The driving force for this increased use is vehicle weight reduction for improved performance, particularly fuel efficiency. In many cases the mechanical properties of the cast aluminum parts are superior to those of the cast iron or wrought steel parts being replaced; however, in some applications, defects in the cast microstructure undermine performance characteristics.

Modern Planning and Control and Virtual Verification of Process Continuity of a New Production Line

2014 ◽  
Vol 708 ◽  
pp. 167-172
Author(s):  
Pavol Božek ◽  
Marek Kňažík ◽  
Vladimír Štollmann
Keyword(s):  
Production Line ◽  
Material Flow ◽  
Flow Simulation ◽  
Simulation Software ◽  
Practical Implementation ◽  
Concept Design ◽  
New Production ◽  
Planning And Control ◽  
And Control

The paper describes one practical implementation of the Digital Factory concept – design of a new production line using modern planning method of virtual testing and control of processes. The project covered graphical facility design, detailed design of operations and material flow simulation. This case study shows facility process planning, commission and in the end finding the optimization rules and corrective actions to increase existing casting line throughput. All phases of the project were carried out using simulation software, duration of the project was 6 months. Simulation software WITNESS has been used for material flow simulation.

Tolerance Simulation of Compliant Sheet Metal Assemblies Using Automatic Node-Based Contact Detection

2008 ◽  
Author(s):  
Kristina Wa¨rmefjord ◽  
Lars Lindkvist ◽  
Rikard So¨derberg
Keyword(s):  
Simulated Data ◽  
Simulation Software ◽  
Contact Detection ◽  
Contact Modeling ◽  
Industrial Case Study ◽  
Critical Dimensions ◽  
Finite Element Software ◽  
Inspection Data ◽  
Variation Simulation

Tolerance simulation is a crucial tool for predicting the outcome in critical dimensions, and is used during early phases of product development in automotive industry. In order to increase the accuracy and the agreement with reality of the predictions even further, variation simulation software offer in some cases the possibility to perform compliant analysis, i.e. the parts are not restricted to be rigid. In compliant analysis contact modeling is an important feature. In this paper a simplified method for automatic contact detection, well suited for tolerance simulations, is suggested. Traditionally, those kinds of non-rigid simulations are very time consuming, but by using this kind of simplified contact modeling in the Monte Carlo simulations, the simulation times can be kept down. The method is tested on an industrial case study. The analyses are done with and without contact modeling and those results are compared to real inspection data. The contact modeling turns out to be an important feature; the correlation between the results with contact modeling and inspection data is much stronger than the correlation for simulations without contact modeling. When using the new contact modeling algorithm the correspondence between simulated data and inspection data is very satisfying and the algorithm seems to be faster than traditional finite element software.

Closed loop identification and control loop reconfiguration: an industrial case study

2001 ◽  
Vol 11 (5) ◽  
pp. 587-599 ◽  
Author(s):  
S. Lakshminarayanan ◽  
G. Emoto ◽  
S. Ebara ◽  
K. Tomida ◽  
Sirish L. Shah
Keyword(s):  
Closed Loop ◽  
Control Loop ◽  
Industrial Case Study ◽  
Closed Loop Identification ◽  
And Control

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.

Forecast of Shrinkage Porosity of Aluminum Wheel Liquid Die Forging in Solidification Process and Process Optimization

2013 ◽  
Vol 690-693 ◽  
pp. 2236-2239
Author(s):  
Hai Bo Yang ◽  
Xing Sheng Zhao ◽  
Wei Zhong Fan ◽  
Xue Wen Chen ◽  
De Ying Xu
Keyword(s):  
Aluminum Alloy ◽  
Process Optimization ◽  
Solidification Process ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Orthogonal Test ◽  
Casting Simulation ◽  
Casting Technology ◽  
Casting Simulation Software

Using ProCast casting simulation software, the solidification process of the Aluminum Alloy steel casting was simulated according to its scene casting process, and the shrinkage porosity defect was forecasted. Based on the simulation, the casting technology was improved using the orthogonal test. An optimized plan was obtained, which provided a reference for the actual production of the casting.

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