Numerical Simulation Life Prediction of Alu- Alloy Die -Casting Dies

2012 ◽  
Vol 472-475 ◽  
pp. 2296-2303
Author(s):  
Xiong Wei Han ◽  
De Ping Chen
Keyword(s):  
Numerical Simulation ◽  
Thermal Stress ◽  
Life Prediction ◽  
Die Casting ◽  
Mathematic Model ◽  
Simulation Software ◽  
Mold Surface ◽  
Casting Technology ◽  
Stress Changes ◽  
Simulation Results

Abstract: The die casting technology has more wide application in the production of a variety of small appliances and cooking utensils. However, it is difficult to set casting technology parameters, and the life of casting die is short. In this study, the numerical simulation software was employed to simulate the aluminum mold. By analyzing temperature field, the temperature changes of the mould surface were predicted in the die-casting cycle. According to the thermal stress simulation and mathematic model, the thermal stress and strain variations were presented in the process of casting, The thermal stress changes of A, B point on the mold surface were compared under the different pouring temperature, die preheat temperature and cooling water temperature. On the basis of the simulation results, the best die casting technology parameters were selected. The life of die casting dies is predicted by mathematical model, and the simulation results agree well with the result of experiment. This study reached the conclusion is that the die life prediction method is reliable.

Shell Die-Casting and its Process Based on Numerical Simulation

2011 ◽  
Vol 233-235 ◽  
pp. 1167-1170 ◽  
Author(s):  
Yao Huang ◽  
Yue Dong ◽  
Yong Huang
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Casting Process ◽  
Velocity Fields ◽  
Shrinkage Cavity ◽  
Variation Trend ◽  
Casting Technology ◽  
Simulation Results ◽  
Die Casting Process ◽  
Temperature And Velocity Fields

In this paper, the distribution and variation trend of temperature and velocity fields were obtained by numerical simulation of the casting process of shell die casting. According to the results of the numerical simulation, the die casting technology was optimized. The sound castings were produced. It was verified that shrinkage cavity and porosity could be reduced by increasing injected pressure and decreasing pouring and mould temperatures. The reliability of numerical simulation of die casting process was proved. In addition, the qualified products were obtained on the basis of the optimized die-casting parameters from the simulation results.

Analysis of HPDC Process with Automobile Part (Oil Pan) by CAE Simulation

2013 ◽  
Vol 753-755 ◽  
pp. 1318-1323 ◽  
Author(s):  
Kwang Kyu Seo ◽  
Hong Kyu Kwon
Keyword(s):  
Die Casting ◽  
Simulation Software ◽  
Filling Process ◽  
Solidification Shrinkage ◽  
Automobile Part ◽  
Computer Aided ◽  
Gate System ◽  
Simulation Results ◽  
Casting Design ◽  
Cae Simulation

In this research, Computer Aided Engineering (CAE) simulation was performed by using the simulation software (AnyCasting) in order to optimize casting design of an automobile part (Oil Pan_7G9E) which is well known and complicated to achieve a good casting layout. The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system.

scholarly journals Numerical Simulation Study on the Front Shape and Thermal Stresses in Growing Multicrystalline Silicon Ingot: Process and Structural Design

Crystals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1053
Author(s):  
Chengmin Chen ◽  
Guangxia Liu ◽  
Lei Zhang ◽  
Guodong Wang ◽  
Yanjin Hou ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Thermal Stress ◽  
Thermal Stresses ◽  
Simulation Method ◽  
Power Ratio ◽  
Radial Temperature ◽  
Front Shape ◽  
Simulation Results ◽  
Insulation Block ◽  
Transient Numerical Simulation

In this paper, a transient numerical simulation method is used to investigate the effects of the two furnace configurations on the thermal field: the shape of the melt–crystal (M/C) interface and the thermal stress in the growing multicrystalline ingot. First, four different power ratios (top power to side power) are investigated, and then three positions (i.e., the vertical, angled, and horizontal positions) of the insulation block are compared with the conventional setup. The power ratio simulation results show that with a descending power ratio, the M/C interface becomes flatter and the thermal stress in the solidified ingot is lower. In our cases, a power ratio of 1:3–1:4 is more feasible for high-quality ingot. The block’s position simulation results indicate that the horizontal block can more effectively reduce the radial temperature gradient, resulting in a flatter M/C interface and lower thermal stress.

scholarly journals Study on Occurrence Mechanism of Coal Pillar in L-Shaped Zone during Fully Mechanized Mining Period and Prevention Technology

2021 ◽  
Vol 2021 ◽  
pp. 1-15
Author(s):  
Zeng-qiang Yang ◽  
Hong-mei Wang ◽  
De-quan Sun ◽  
Xian-jian Ma ◽  
Ming-bao Xu ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Rock Burst ◽  
Dynamic Load ◽  
Static Load ◽  
Coal Pillar ◽  
Simulation Software ◽  
In Situ Investigation ◽  
Simulation Results ◽  
Occurrence Mechanism

In order to study the occurrence mechanism of rock burst in L-shaped zone during a fully mechanized mining period, the No. 705 working face which is located in Baojishan Colliery is taken as a typical engineering background. By means of in situ investigation, theoretical analysis, numerical simulation, in situ tests, and relevant monitoring methods, the occurrence mechanism of rock burst and corresponding prevention technology are studied. The results show that a coal pillar with some confining pressure in the L-shaped zone is established by FLAC3D numerical simulation software, and the numerical simulation results indicate that the change in static load has a greater effect than dynamic load on coal pillar unstable failure; the static load plays a role in storing energy, and dynamic load plays a role in inducing rock burst; the bolt-mesh-cable support and high-pressure water jet unloading combined technology is put forward to prevent rock burst in roadways, and the numerical simulation results show that stress distribution of surrounding rock meets the model of strong-soft-strong (3S) structure, and the moment distribution is reasonable. In the follow-up mining, a limit value of coal fines is used to determine that this measure is a reasonable method to prevent rock burst. The study conclusions provide theoretical foundation and new guidance for preventing rock burst by synergistic effect technology in roadways.

scholarly journals Study on Mechanical Properties of Submunition’s Ribbon Straightening Section

2020 ◽  
Vol 2020 ◽  
pp. 1-17
Author(s):  
Dong-ze Qin ◽  
Wei Zhang ◽  
Shu-Yun Zhang ◽  
Tian-Ji Guo ◽  
Shui-Yuan Pei ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Tensile Force ◽  
Physical Structure ◽  
Simulation Software ◽  
Tension Test ◽  
Response Characteristics ◽  
Experimental Scheme ◽  
Drop Velocity ◽  
Simulation Results

The humanitarian damage caused by the unexploded submunitions is one of the hot issues of concern to the international community at present. A portion of the submunition that did not explode was caused by a break at the connection between the ribbon riveting and the fuze. According to the physical structure of the submunition and the trajectory into which it was ejected, we analyzed the forces of the submunition in flight, deduced the related mathematical models, and clarify the key elements of the mechanics. In this paper, the commercial simulation software was used to calculate the mechanical properties of the ribbon. And the variation regularity between drop velocity and straightening force of ribbon are revealed. And the response characteristics of different material ribbon with different sizes of riveting holes and riveting joints under tensile action were simulated. The simulation results show that, in the trajectory environment with 30 m/s~55 m/s typical stream speed, the tensile force of the ribbon is less than 300 N, and the application concentration of the connecting parts of the riveting joint and the ribbon will not cause the failure of the kevlar ribbon, but it will cause the failure of the nylon ribbon. In order to verify the variation of the tension of kevlar ribbons in different trajectory environments, we designed the experimental scheme of tension test of the ribbon straightening section of submunition and conducted experiments. Experimental results and numerical simulation results revealed the same law. This paper provides effective technical support for solving the problem of unexploded submunitions.

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.

Numerical simulation on sprue distributions during cladding casting process

2016 ◽  
Vol 26 (8) ◽  
pp. 2340-2354 ◽  
Author(s):  
Xing Han ◽  
Haitao Zhang ◽  
Bo Shao ◽  
Dongtao Wang ◽  
Longgang Cheng ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Casting Process ◽  
Mathematic Model ◽  
Melt Flow ◽  
Content Type ◽  
Metallurgical Bonding ◽  
Flow Heat ◽  
Simulation Results ◽  
Interface Bonding Strength

Purpose The purpose of this paper is to investigate the influence of sprue distributions on the flow field and temperature field of the cladding casting process and verify the simulation results by experiments. Design/methodology/approach A steady-state mathematic model for the coupling of fluid flow, heat transfer and solidification to describe the process of cladding casting was present. The effect of sprue distributions on melt flow and temperature field was discussed. Based on the numerical simulation results, the cladding billet was prepared successfully. Moreover, the model has been verified against by temperature measurements during the cladding casting process. Findings There is a good agreement between the measured and calculated results. The homogeneity of melt flow determines the formability of cladding billets and circular temperature difference affects the bonding of the two alloys. The AA4045/AA3003 cladding billet with no defects in size of f140/f110 mm was fabricated successfully. The alloy elements diffused across the interface and formed diffusion layer with a thickness of 15 µm. The interface bonding strength is higher than the tensile strength of AA3003, indicating the metallurgical bonding between two alloys. Research limitations/implications The casting parameters are limited to the aluminum alloy cladding billet in size of f140/f110 mm in this paper. Originality/value There are few reports of cladding billet, which are used to prepare condense pipes of automotive engines. The effect of distribution schemes on the cladding casting process is rarely studied.

Simulation Study on HPDC Process for Automobile Part with Aluminum Alloy

2013 ◽  
Vol 761 ◽  
pp. 79-82 ◽  
Author(s):  
Hong Kyu Kwon ◽  
Kwang Kyu Seo
Keyword(s):  
Die Casting ◽  
Simulation Software ◽  
Filling Process ◽  
Solidification Shrinkage ◽  
Cooling Systems ◽  
Automobile Part ◽  
Gate System ◽  
Simulation Results ◽  
Pressure Die Casting ◽  
Casting Design

In this research, in order to optimize casting design of an automobile part (Gear Box), Computer Aided Engineering (CAE) was performed by using the simulation software (Z-Cast). The simulation results were analyzed and compared with experimental results. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making better permanent High Pressure Die Casting (HPDC) mold, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

Application of Numerical Simulation on Cast-Iron Pneumatic Hammer Housing

2011 ◽  
Vol 474-476 ◽  
pp. 432-435
Author(s):  
Guo Fa Mi ◽  
Li Lin Chen ◽  
Bao Zhong Liu ◽  
Hai Yan Wang
Keyword(s):  
Numerical Simulation ◽  
Cast Iron ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Gating System ◽  
Pneumatic Hammer ◽  
Shrinkage Defects ◽  
Simulation Results ◽  
D Model

The Pro/E software was used to generate 3-D model of pneumatic hammer housing casting. The solidification process of the casting was simulated by the numerical simulation software, View Cast. The location and scale of the shrinkage defects were shown in the results. The risers were designed by the View Cast software based on the simulation results. The reasonable risers were obtained after the optimization on the numerical simulation. And the parameters of gating system were got according to the simulation results calculated by the gating system designing function of View Cast. Then the solidification results demonstrated that the risers and pouring system could be planned by View Cast effectually. The reasonable casting process was obtained and the process has been proofed by the productive practice.

scholarly journals Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve Six Sigma Quality Product Using Numerical Simulation Approach

2021 ◽  
Vol 11 (1) ◽  
pp. 97-109
Author(s):  
Suraj R. Marathe ◽  
Dr. Carmo E. Quadros
Keyword(s):  
Numerical Simulation ◽  
High Pressure ◽  
Molten Metal ◽  
Die Casting ◽  
Injection Pressure ◽  
Simulation Software ◽  
Holding Time ◽  
Simulation Approach ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

A numerical simulation approach is proposed to predict the optimal parameter setting during high pressure die casting. The contribution from the optimal parameters, the temperature, showed more influence on the casting quality than the other parameters. This study’s outcome was beneficial for finding the solution for casting defects that occurs due to incorrect setting of process parameters in die casting. Thus, a combination of numerical optimisation techniques and casting simulation serves as a tool to improve the casting product quality in die casting industries. This paper aims to analyse and optimise critical parameters like injection pressure, molten metal temperature, holding time, and plunger velocity, contributing to the defects. In this research paper, an effort has been made to give optimal pressure, temperature, holding time, and plunger velocity parameters using ProCAST simulation software that uses finite element analysis technology. Numerical analysis for optimising the parameters by varying the temperature of molten metal, injection pressure, holding time, and plunger velocity,  concerning solidification time at hot spots, is an essential parameter for studying the defect analysis in the simulated model.

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