Modeling Analysis and Optimization of Sand Casting Process

In this research paper, the sand casting process of a cover-type part for wind turbine was investigated with ProCAST software . The cover-type casting part is big in two dimensions and it is heavy in some local positions where shrinkage cavity and porosity are very likely to from. A non-uniform mesh is used corresponding to the non-uniform wall thickness. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced

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Numerical Modeling on Sand Casting Process of a Wind Turbine Part

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.121-126.1367 ◽

2011 ◽

Vol 121-126 ◽

pp. 1367-1371 ◽

Cited By ~ 2

Author(s):

Qing Ming Chang ◽

Yin Kai Yang ◽

Xia Chen ◽

Chang Jun Chen ◽

Si Qian Bao

Keyword(s):

Numerical Simulation ◽

Numerical Modeling ◽

Wind Turbine ◽

Research Work ◽

Casting Process ◽

Mold Filling ◽

Sand Casting ◽

Shrinkage Cavity ◽

Pouring Temperature ◽

Filling And Solidification

In this research work, ProCAST software is employed to study the sand casting process of a box-type part for wind turbine. The casting part is big in size, non-uniform in wall thickness, and heavy in some local positions. Shrinkage cavity and porosity are very likely to from at these locations. By numerical simulation, the influence of the parameters such as pouring temperature, chills, riser on mold filling and solidification is analyzed. Simulation researches reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced.

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Study on the Causes and Prevention Measures of Shrinkage Defects of Heavy V-Belt Pulley in the Production

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.722.231 ◽

2014 ◽

Vol 722 ◽

pp. 231-234

Author(s):

Gui Qin Jin ◽

Tao Yan ◽

Cui Feng Chen

Keyword(s):

Chemical Composition ◽

Hot Spot ◽

Casting Process ◽

Shrinkage Porosity ◽

Shrinkage Cavity ◽

Optimized Design ◽

Prevention Measures ◽

Pouring Temperature ◽

Performance Requirements ◽

Shrinkage Defects

Shrinkage cavity and shrinkage porosity, often occurring during the production of heavy v-belt pulley roughcast, may lead to the decrease of the pulley performance and further result in casting rejection. Therefore, it is necessary to study the causes and prevention measures of shrinkage defects of the casting. The material of V-belt pulley roughcast at issue is HT250 and it adopts resin sand casting process. With a large amount of practice in workshop and times of revision of the design of foundry technology, we have found that the shrinkage in the hot spot of heavy v-belt pulley roughcast can be reduced or even eliminated to fully meet the performance requirements with a moderate control of pouring temperature and speed, an optimized design of foundry technology, and a strict limitation of chemical composition. This finding will bring illumination to the production process of other heavy pulley roughcast.

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Numerical Simulation of Chilled Cast Iron Camshaft in Sand Casting Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.44-47.117 ◽

2010 ◽

Vol 44-47 ◽

pp. 117-121

Author(s):

Bin Feng He ◽

Zhu Qing Zhao

Keyword(s):

Numerical Simulation ◽

Cast Iron ◽

Solidification Process ◽

Casting Process ◽

Mold Filling ◽

Sand Casting ◽

Simulation Results ◽

Improved Technology ◽

Filling And Solidification ◽

Chilled Cast Iron

There are many kinds of casting defects such as insufficient pouring, cooling separation, crack, and shrinkage and soon on were formed in the mold filling and the solidification process, which affect the final casting performance. Based on the mathematical models of mold filling and solidification process, the numerical simulation of chilled cast iron camshaft in sand casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkages were predicted. According to the simulation results, an improved technology is proposed, and the shrinkages were eliminated efficiently. The simulation results are in good agreement with practical.

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Shell Die-Casting and its Process Based on Numerical Simulation

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.233-235.1167 ◽

2011 ◽

Vol 233-235 ◽

pp. 1167-1170 ◽

Cited By ~ 1

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.

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Casting Process and Simulation of K19 Cylinder Block

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.602-605.311 ◽

2014 ◽

Vol 602-605 ◽

pp. 311-315

Author(s):

Yi Chen ◽

Gang Yang ◽

Yi Yang ◽

Kang Sheng Wang ◽

Chen Guang Lu

Keyword(s):

Mechanical Properties ◽

Casting Process ◽

Cylinder Block ◽

Shrinkage Cavity ◽

High Quality ◽

Actual Experiment ◽

Engine Cylinder ◽

Numerical Software ◽

Superior Mechanical Properties ◽

Simulation Results

Cylinder blocks are the most important parts of engine, and their qualities will fundamentally determine the efficiency of engine. In this work, the casting process of K19 engine cylinder block was studied. A casting process was designed and assessed by the numerical software MAGMA to produce cylinder block castings. An actual experiment of casting was carried out and the mechanical properties of the casting were examined. The simulation results show the liquid metal smoothly fills the casting mold and no shrinkage cavity and porosity are formed in the castings. The cylinder block produced by the actual experiment exhibits superior mechanical properties to common ones, which proves the casting process designed is suitable for producing high quality cylinder block castings. The research shows that numerical simulation can provide very useful guidance for the production of castings

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OPTIMISATION OF SAND CASTING PROCESS FOR IMPELLER USING TAGUCHI METHODOLOGY

NED University Journal of Research ◽

10.35453/nedjr-ascn-2019-0041 ◽

2020 ◽

Vol XVII (2) ◽

pp. 23-33

Author(s):

Faisal Hafeez ◽

Salman Hussain ◽

Wasim Ahmad ◽

Mirza Jahanzaib

Keyword(s):

Surface Roughness ◽

Surface Defects ◽

A356 Alloy ◽

Casting Process ◽

Sand Casting ◽

Gate Length ◽

Taguchi Methodology ◽

Confirmatory Tests ◽

Binder Ratio ◽

Response Measures

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

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Experimental and simulation analysis on multi-gate variants in sand casting process

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2020.12.006 ◽

2021 ◽

Vol 62 ◽

pp. 119-131

Author(s):

I. Rajkumar ◽

N. Rajini ◽

A. Alavudeen ◽

T. Ram Prabhu ◽

S.O. Ismail ◽

...

Keyword(s):

Simulation Analysis ◽

Casting Process ◽

Sand Casting

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A PERCOLATION MODEL OF DIAGENESIS

International Journal of Modern Physics C ◽

10.1142/s0129183102003176 ◽

2002 ◽

Vol 13 (03) ◽

pp. 319-331 ◽

Cited By ~ 7

Author(s):

S. S. MANNA ◽

T. DATTA ◽

R. KARMAKAR ◽

S. TARAFDAR

Keyword(s):

Numerical Simulation ◽

Critical Behavior ◽

Sedimentary Rocks ◽

Two Dimensions ◽

Percolation Model ◽

Type Model ◽

Stable Configuration ◽

Critical Percolation ◽

Restructuring Process ◽

Simulation Results

The restructuring process of diagenesis in the sedimentary rocks is studied using a percolation type model. The cementation and dissolution processes are modeled by the culling of occupied sites in rarefied and growth of vacant sites in dense environments. Starting from sub-critical states of ordinary percolation the system evolves under the diagenetic rules to critical percolation configurations. Our numerical simulation results in two dimensions indicate that the stable configuration has the same critical behavior as the ordinary percolation.

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