Defects Analysis and Improvement for Electricmotorcar Aluminum Alloy Wheel by Gravity Casting

2011 ◽  
Vol 189-193 ◽  
pp. 3880-3885 ◽  
Author(s):  
Fei Fei Wang ◽  
Yan Wei Sui ◽  
Yao Jian Ren ◽  
Xin Zhao ◽  
Zhi Sun
Keyword(s):  
Process Parameters ◽  
Solidification Process ◽  
Technological Parameters ◽  
Original Process ◽  
Gravity Casting ◽  
Alloy Wheel ◽  
Hole Defect ◽  
Porosity Defects ◽  
Defects Analysis ◽  
Filling And Solidification

Analysis the electricmotorcar aluminum wheels’ hole defect on macroscopic and microscopic, observed that the main defects、concentrated site and the main alloy phase. Combined with the local casting technological parameters, the filling and solidification process of aluminium alloy hub was simulated by using Anycasting software. The results showed that: castings filling smoothly, at the junction of the spoke and the rim and the hub central are easy to produce casting defects. Using the optimized process parameters that is lower pouring temperature, higher pouring height and set the vent to experiment, after comparing the results with the original process known, Shrinkage and porosity defects decreased, but there are still some degree of defects, indicating optimized process parameters have some effect.

Simulation of Filling and Solidification Processes of Rump Pan by Procast

2013 ◽  
Vol 785-786 ◽  
pp. 1212-1215
Author(s):  
Tao Liang ◽  
Yin Hu Qu ◽  
Xin Feng Liu ◽  
Feng Wang ◽  
Min Hua Zhang
Keyword(s):  
Process Parameters ◽  
Solidification Process ◽  
Shrinkage Porosity ◽  
The Body ◽  
Shrinkage Cavity ◽  
Gating System ◽  
Optimal Process ◽  
Solidification Processes ◽  
Filling And Solidification

The rump pan is the body and the load-carry device of Scraper conveyer. the material is ZG30MnSi. In order to improve the life of the casting.this paper simulated filling and solidification process of rump pan by Procast software,and predicted the position of shrinkage cavity and shrinkage porosity in castings.Then through improving gating system and add reasonable risers, optimal process parameters scheme is got.

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.

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.

Research on Intelligent Optimization Algorithm for the Hot Press Insulation of Generator Stator Bar

2017 ◽  
Vol 868 ◽  
pp. 265-270 ◽  
Author(s):  
Xiao Dong Tan ◽  
Ling Hao Kong ◽  
Dao Ru Li
Keyword(s):  
Neural Network ◽  
Process Parameters ◽  
Solidification Process ◽  
Production Quality ◽  
Accurate Estimate ◽  
Heating Time ◽  
Technological Parameters ◽  
Intelligent Optimization Algorithm ◽  
The Relationship ◽  
Generator Stator

As the heart of generator, stator bar’s production quality will directly influence the whole generator’s quality. We researched heating and solidification process of stator bar at the beginning to clarify the relationship between heating time and temperature. BP neural network toolbox in MATLAB platform was used to build neural network model which will relatively accurate estimate bar’s resistance with four process parameters. Through the resistance, people can find out the best technological parameters before actually production. We used some data collected from one factory as learning data. Others were test data, used to illustrate the rationality of the model, which can forecast insulation resistance value in later production, finding the optimal process parameters.

Numerical Simulation Analysis on Shrinkage and Porosity of ZL101A Alloy Mechanism Box

2011 ◽  
Vol 704-705 ◽  
pp. 28-32
Author(s):  
Yan Jun Zhou ◽  
Ke Xing Song ◽  
Yan Min Zhang ◽  
Xiu Hua Guo
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Solidification Process ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Analysis Procedure ◽  
Liquid Distribution ◽  
Gravity Casting ◽  
Porosity Defects

The Shrinkage and porosity of ZL101A alloy mechanism box prepared by sand gravity casting process was investigated. The solidification process was simulation analysis by using InteCAST software and the original casting process was optimized based on the above simulated results. The results showed that the shrinkage and porosity defects’ position of ZL101A alloy mechanism box were accurately predicted by the analysis procedure which was from liquid distribution to shrinkage formation and then to Niyama shrinkage porosity. The shrinkage and porosity of the ZL101A alloy mechanism box prepared by optimized process were clearly reduced and the distribution of them was reasonable. Keywords: InteCAST software;ZL101A; Mechanism box; Shrinkage and porosity; Numerical simulation

The Numerical Simulation and Optimization of Squeeze Casting Process for Producing Magnesium Wheels

2011 ◽  
Vol 299-300 ◽  
pp. 955-961
Author(s):  
Rong Qing Yao ◽  
Hong Qiang Tang
Keyword(s):  
Squeeze Casting ◽  
Orthogonal Experiment ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation And Optimization ◽  
Alloy Wheel ◽  
Best Parameter ◽  
Cast Property ◽  
Filling And Solidification ◽  
Squeeze Casting Process

The simulation of squeeze casting process of a magnesium alloy wheel was practice. Using professional casting software, the temperature field during filling and solidification process, and then the potential defects were forecasted and previewed. It was found that there would be shrinkage defects at the center and the junctions between the rim and the spokes of the wheel. It is better to choose a mould temperature for a better cast property at meet of full-filling. Number of programs are analyzed and compared through orthogonal experiment. And the best parameter team is educed through analysis. It is confirmed that the potential micro-shrinkage is reduced by simulated again using the best parameter team. And the cast property is enhanced.

Comparison of various gating systems for investment casting of hydraulic retarder impeller with complex geometry

2020 ◽  
pp. 095440542097199
Author(s):  
Fei Li ◽  
Yingchun Wang ◽  
Donghong Wang ◽  
Yanjie Zhao ◽  
Chengkang Qi ◽  
...  
Keyword(s):  
Investment Casting ◽  
Complex Geometry ◽  
Complex Structure ◽  
Solidification Process ◽  
Shrinkage Porosity ◽  
Gating System ◽  
Porosity Defects ◽  
Simulation Results ◽  
Hydraulic Retarder ◽  
Filling And Solidification

Due to the complex structure and thin thickness of the guide vane edge of the hydraulic retarder impeller, the casting defects such as shrinkage porosity and misrun are usually formed during casting, which have a close relationship with the filling and solidification process. In this work, the filling and solidification processes of impeller in various gating systems, named case 1 to 3, were simulated and the distribution characteristics of potential shrinkage porosity defects were predicted by ProCAST software based on the mathematical models, boundary conditions, and parameters of investment casting. The simulation results show that the aim of complete filling of the impeller can be achieved by using all of the three gating systems. However, only the case 3 gating system consisted with one sprue riser and four feeding risers can provide the impeller with suitable feeding channel in melt solidification process. Therefore, no predicted shrinkage porosities form in the impeller because the defects can transfer to the gating system during solidification. The optimized gating system have been verified by experiment, and the rapid casting of the impeller has been realized by using 3D printed polystyrene patterns. The results of visual and X-ray inspections show that both the misrun and shrinkage porosity defects were eliminated in the actually final cast, which matched well with the numerical simulation results for the investment casting of the impeller. Many experiment results of the new product show that these optimization gating system are very helpful to reduce the casting defect and to improve the product quality.

scholarly journals Development of Universal Mould Geometry for the Teeming of Cylindrical Iron-Base Alloy Ingots

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 471
Author(s):  
Josef Odehnal ◽  
Pavel Ludvík ◽  
Tomáš Studecký ◽  
Pavel Michálek
Keyword(s):  
Alloy Steel ◽  
Base Alloy ◽  
Cast Steel ◽  
Solidification Process ◽  
High Alloy ◽  
High Alloy Steel ◽  
Iron Base Alloy ◽  
Steel Grades ◽  
Borated Stainless Steel ◽  
Filling And Solidification

The presented work is aimed at developing a mould geometry suitable for casting both low- and high-alloy steel grades into 500 kg experimental ingots. The high Height-to-Diameter (H/D)-ratio mould currently used in COMTES FHT Inc. served as a reference and for finite element method simulations (FEM) of the filling and solidification process. The optimized mould geometry, balancing the porosity and segregations, was determined using MAGMA software. Four different steel grades were defined for the simulation. Case studies were carried out for 34CrNiMo6 (W.Nr. 1.6582), DHQ8, CB2 and borated stainless steel grades ranging from low-alloy steel to high-alloy steel. Extended user-defined criteria and verified boundary conditions were used to predict the formation of A-segregations in cast steel. Both primary (PDAS) and secondary (SDAS) arm spacings were modelled as well. The optimized mould shape and the casting assembly were designed based on the simulation results.

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.

Analysis of Shrinkage Characteristics of Aluminium Silicon Alloy

2016 ◽  
Vol 16 (3) ◽  
pp. 163-171 ◽  
Author(s):  
Syed Ferhathullah Hussainy ◽  
Mohd. Viquar Mohiuddin ◽  
P. Laxminarayana ◽  
S. Sundarrajan ◽  
A. Krishnaiah
Keyword(s):  
Solidification Process ◽  
Literature Survey ◽  
Extensive Literature ◽  
Industrial Environment ◽  
Silicon Alloy ◽  
Casting Yield ◽  
Cavity Filling ◽  
Alloy Castings ◽  
Filling And Solidification ◽  
Critical Aspects

AbstractAnalysis of shrinkage characteristics of Aluminium-Silicon alloy was studied theoretically and experimentally. The Aluminium alloys considered in the study are A413 (LM6), A360 (LM9) and A380 (LM24). Extensive literature survey has suggested that cavity filling and solidification process are two most critical aspects to produce high quality casting components. A statistical model of parameters and response to understand the influence of parameters on shrinkage and casting yield studies has been presented. Experiments were conducted in foundry in industrial environment to produce commercially treated aluminium alloy castings in sand mould. Alloy was found to be most significant factor influencing shrinkage. The yield of casting was improved using insulating and exothermic sleeves. Solidification time of exothermic riser was 10 % more than insulated riser. Thus, in order to produce radiographic quality casting a theoretical and experimental method is presented so that number of trials in foundry is reduced which leads to increased reliability and productivity. Study also shows that by using sleeves considerable metal is saved, energy saving during melting, improved quality, reduced cost and increased capacity of plant can be achieved.

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