Design and Simulation Optimization of Casting Process for Aluminum Alloy Engine Cylinder Head

2014 ◽  
Vol 494-495 ◽  
pp. 593-597
Author(s):  
Xiu Xiu Pan ◽  
Yi Yang ◽  
Gang Yang ◽  
De Qiang Yin ◽  
Yu Zhou
Keyword(s):  
Cylinder Head ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Production Cycle ◽  
Modeling Process ◽  
Engine Cylinder ◽  
Filling And Solidification ◽  
Trial Cost

The liquid metal filling and solidification process of aluminum engine cylinder head in different gating system during casting process was simulated by casting simulation software MAGMAsoft. The simulation results showed that the best pouring process contains the bottom note type casting and the placement of combustion chamber side, so that we could obtain a simple modeling process, and significantly shorten the trial production cycle, as well as the trial cost of the piston, and improve the quality of the cylinder head.

Finite Element Analyses and Model of Squeeze Casting Process for Producing Magnesium Wheels

2012 ◽  
Vol 557-559 ◽  
pp. 2299-2302
Author(s):  
Chang Jiang Lin ◽  
Yin Jin ◽  
Hong Qing Tang
Keyword(s):  
Finite Element ◽  
Squeeze Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Die Design ◽  
Finite Element Analyses ◽  
Alloy Wheel ◽  
Filling And Solidification ◽  
Squeeze Casting Process

A finite element equation has been developed to simulate the squeeze casting process of a magnesium alloy wheel, a parametric model has been established to confirm the temperature field during filling and solidification process. The model can be used to investigate the effects of die design and process parameters (die temperature, pressure etc.) on the quality of castings.

Foundry Technique Designing of the Nodular Cast Iron Casting

2014 ◽  
Vol 1004-1005 ◽  
pp. 1162-1165
Author(s):  
Bin Feng He
Keyword(s):  
Solidification Process ◽  
Casting Process ◽  
Nodular Cast Iron ◽  
Simulation Software ◽  
Casting Simulation ◽  
Filling Process ◽  
Original Technique ◽  
Correct Determination ◽  
Filling And Solidification ◽  
Casting Simulation Software

The traditional method has been used to the foundry technique for the melt block mobile plate. The pouring position,the parting face and some of the casting parameters were determined, such as the allowance for finish, stripping taper, the rate of shrinkage and soon on. The commercial casting simulation software was introduced into the casting process, the filling and solidification process were calculated by it. The results shown that there are some shrinkage exists in the original technique and the filling process were inordinate. The gating system was optimized and according to the simulation results, the shrinkages in the original technique were eliminated and the filling process is smoothly which could help the designer to make a correct determination.

Computer Simulation of the Filling Process of Air Intake Hood Based on ProCAST

2012 ◽  
Vol 487 ◽  
pp. 327-331
Author(s):  
Han Wu Liu ◽  
Fan Feng ◽  
Chuan Li Yan ◽  
Xian Feng Zheng
Keyword(s):  
Aluminum Alloy ◽  
Geometric Modeling ◽  
High Speed ◽  
Solidification Process ◽  
Casting Process ◽  
Alloy Sheet ◽  
Simulation Software ◽  
Production Cycle ◽  
Air Intake ◽  
The Impact

The intake hood is the part which riveted in the external skin of the aircraft. During the flight of the aircraft, the engine casing is cooled down by the high-speed airflow which flows through the air intake duct. As the components suffer the impact of the high-speed airflow, the appearance of the intake hood must meet the requirements of the aerodynamic property. At the same time, its manufacturing quality has a certain impact on the aerodynamic performance of the aircraft, so its synthetic mechanical property is required high. The traditional air intake hoods are block-combination welded by the aluminum alloy sheet. Its complicated working procedure, long production cycle, high costs and the difficult weld methods make it difficult to guarantee the welding quality. In order to improve the useful life of the air intake hood, to lower the production difficulty and to solve the quality risks in the production due to the method of weld, in this article, the high-strength aluminum alloy ZL101A and plaster mould investment casting were used to mold the intake hood based on the three-dimensional geometric modeling of the air intake hood by software Pro/E, and then, the filling and solidification process of the air intake hood was simulated by the casting simulation software ProCAST to predict the defects such as misrun, cold shut, wrapped in air, the thermal centre and the residual stress and deformation which were displayed in the filling and the solidification processes of the metal. Then, the casting process of the air intake hood can be optimized to achieve a decrease or avoid casting defects in the actual production.

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.

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.

scholarly journals Study of the Effect of Carbon on the Contraction of Hypo-Peritectic Steels during Initial Solidification by Surface Roughness

Metals ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 982 ◽  
Author(s):  
Dazhi Pu ◽  
Guanghua Wen ◽  
Dachao Fu ◽  
Ping Tang ◽  
Junli Guo
Keyword(s):  
Surface Roughness ◽  
Cooling Rate ◽  
Solidification Process ◽  
Casting Process ◽  
Continuous Casting Process ◽  
Peritectic Steel ◽  
Laser Confocal Microscope ◽  
Initial Solidification

In the continuous casting process, the shrinkage of the peritectic phase transition during the initial solidification process has an important influence on the surface quality of peritectic steel. The initial solidification process of 0.10C%, 0.14C%, and 0.16C% peritectic steels was observed in situ by a high temperature laser confocal microscope, and the contraction degree during initial solidification was characterized by surface roughness. The results showed that under the cooling rate of 20 °C/s, the surface roughness value Ra(δ/γ) of 0.10C% peritectic steel was 32 μm, the Ra(δ/γ) value of 0.14C% peritectic steel was 25 μm, and the Ra(δ/γ) value of 0.16C% peritectic steel was 17 μm. With increasing carbon content, the contraction degree of the δ→γ transformation decreased, and the value of the surface roughness Ra(δ/γ) declined. Therefore, surface roughness can characterize the contraction degree of the δ→γ transformation in the initial solidification process of peritectic steel under the condition of a large cooling rate.

Melt Mold Casting Process Optimization of Train Coupler Based on ProCAST

2018 ◽  
Vol 764 ◽  
pp. 312-322
Author(s):  
Cheng Jun Wang ◽  
Jin Yan Chen ◽  
Yu Zhe Shen
Keyword(s):  
Process Optimization ◽  
Simulation Analysis ◽  
Solidification Process ◽  
Casting Process ◽  
Process Measures ◽  
Technical Requirements ◽  
Shrinkage Defects ◽  
Mold Casting ◽  
Cae Simulation ◽  
Filling And Solidification

In order to solve production defects such as shrinkage and porosity inside a certain train coupler casting in Anhui Xinhong Machinery Co.,Ltd., the main reasons of defects are found through the process of CAE simulation analysis and physical X ray detection to determine the location and morphology of casting defects and to reflect the actual situation of coupler filling and solidification process. The main reasons are found as follows: uneven thickness of casting structure, insufficient original gating and feeding system and etc. Through the process optimization and apply multidimensional vibration, then test validation, the train coupler casting which meets the technical requirements has been successfully produced, ensuring the smooth mass production of the company. ProCAST numerical simulation results have confirmed the rationality of the proposed work in optimization process measures in reducing and eliminating the shrinkage defects.

Solidification and Microstructure Simulation of A356 Aluminum Alloy Casting

2021 ◽  
Vol 1033 ◽  
pp. 18-23
Author(s):  
Li Tong He ◽  
Yi Dan Zeng ◽  
Jin Zhang
Keyword(s):  
Aluminum Alloy ◽  
Solidification Process ◽  
Casting Process ◽  
Uniform Structure ◽  
A356 Aluminum Alloy ◽  
Aluminum Alloy Casting ◽  
Alloy Casting ◽  
Shrinkage Defects ◽  
A356 Aluminum ◽  
Filling And Solidification

To obtain an A356 aluminum alloy casting with a uniform structure and no internal shrinkage defects, ProCAST software is used to set different filling and solidification process parameters for an A356 aluminum alloy casting with large wall thickness differences, And multiple simulations are conducted to obtain optimized casting process; then, based on the process, the microstructure of the thickest and thinnest part of the casting are simulated. The size, morphology, and distribution of the simulated microstructure of the thinnest part and the thickest part of the casting are very similar. The simulated microstructure is similar to that of the actual casting. This shows that castings with uniform structure and no internal shrinkage defects can be obtained through the optimized casting process .

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 Mold Filling and Solidification Process for Beam Blank Continuous Casting

2012 ◽  
Vol 538-541 ◽  
pp. 506-509
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang
Keyword(s):  
Velocity Field ◽  
Continuous Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Filling Process ◽  
Continuous Casting Mold ◽  
Commercial Code ◽  
Solidification Speed ◽  
Filling And Solidification

Mold filling and solidification of molten steel for 750mm×450mm×300mm continuous casting mold of single SEN and double SEN are simulated by using CFD commercial code Flow-3d. The distributing diagrams of velocity field and temperature field and the location and shape diagrams of free-surface during mold filling process are obtained. Influences of single SEN model and double SEN model on velocity field and solidification are analyzed. It is found that double SEN model can lighten circumfluence intensity at the upper of mold, quicken solidification speed of steel liquid in the mold, which is favorable to improving the quality of billet and enhancing pull speed.

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