Application of Numerical Simulation and Optimization on Tensioner Pulley Bracket

2012 ◽  
Vol 529 ◽  
pp. 186-189
Author(s):  
Hong Yan Nan ◽  
Li Lin Chen ◽  
Guo Fa Mi ◽  
Jiao Ma
Keyword(s):  
Casting Process ◽  
Casting Defects ◽  
Optimization Scheme ◽  
Simulation And Optimization ◽  
Casting Technology ◽  
Solidification Simulation ◽  
Shrinkage Defects ◽  
Mould Filling ◽  
Simulation Results ◽  
Filling Simulation

This article is about casting process of tensioner pulley bracket, which includes solidification simulation, mould filling simulation and defect forecast, using ViewCast software. The scale and location of the shrinkage defects were shown in simulation results. Solidification results demonstrated that the casting defects were not eliminated by the casting technology. The optimized scheme was obtained by replacing and adding chills. The optimization scheme was calculated and the simulation results shown that the reasonable casting process was obtained and the process has been proofed by the productive practice.

Numerical Simulation and Optimization on Casting Process of Mould Clamping Board Using a Nodular Cast Iron

2011 ◽  
Vol 415-417 ◽  
pp. 1637-1642
Author(s):  
Guo Fa Mi ◽  
Li Lin Chen ◽  
Chang Yun Li
Keyword(s):  
Computer Aided Design ◽  
Casting Process ◽  
Nodular Cast Iron ◽  
Casting Defects ◽  
Simulation And Optimization ◽  
Casting Technology ◽  
Solidification Simulation ◽  
Mould Filling ◽  
Simulation Results ◽  
Filling Simulation

A three-dimensional Computer Aided Design (CAD) model of the mould clamping board is established by Pro/E software. The ViewCast program is utilized to study casting processes of solidification and mould-filling in order to design the risers and optimize the casting technology. Based on the solidification simulation, the casting defects such as shrinkage and porosity are forecasted visually in diagrams with the help of ViewCast. Reasonable risers are designed on the basis of the solidification simulation. The mould-filling simulation verify the metal fluid gates the mould smoothly and reposefully. The filling simulation results of initial casting scheme show that this casting technology is improper. The optimized scheme is completed through the filling simulation and a modified casting technology is obtained. The parting gating system is used to pouring the mold of clamping board. The simulation results of optimized scheme indicate that the shrinkage are eliminated effectively and the metal fluid fill the mold smoothly. Experimentally, the casting confirms that the optimized method is very useful in reducing the casting defects and improving the product quality.

Casting Process Design and Simulation of Large Cast Steel Bracket

2019 ◽  
Vol 815 ◽  
pp. 125-130
Author(s):  
Jia Ji Xiong ◽  
Fan Lin Meng ◽  
Qing Jin Liang ◽  
Chong Cao
Keyword(s):  
Process Design ◽  
Manufacturing Process ◽  
Cast Steel ◽  
Casting Process ◽  
Casting Defects ◽  
Optimization Scheme ◽  
Sand Core ◽  
Steel Cast ◽  
Simulation Results ◽  
Filling And Solidification

The casting process design of large cast steel supports is carried out, and the special integrated sand core and forged steel cast lugs are used to simplify the cavity manufacturing process. The ProCAST software was used to simulate the casting process of the stent, simulating the filling and solidification of the casting, and predicting the occurrence of defects such as shrinkage and shrinkage of the casting. According to the simulation results, the cause of the defects is analyzed, and the casting process of the stent is optimized. The simulation results show that the optimization scheme effectively reduces the casting defects and the surface of the stent is free from defects.

Solidification Simulation of Melt-Cast Explosive under Pressurization

2011 ◽  
Vol 704-705 ◽  
pp. 71-75 ◽  
Author(s):  
Dong Lei Wang ◽  
Zhi Yi Xie ◽  
Wen Xu Sun ◽  
Yong Huang
Keyword(s):  
Pore Formation ◽  
Thermodynamic Characteristics ◽  
Casting Process ◽  
Solidification Simulation ◽  
Shrinkage Cracks ◽  
Shrinkage Defects ◽  
Field Temperature ◽  
Simulation Results ◽  
Temperature And Pressure ◽  
Explosive Process

The flow field, temperature field and stress field on the melt-cast explosive process have been studied by using software of Procast combined with experimental method，from which the thermodynamic characteristics of the explosives melt-casting process has been researched. The simulation results show that the charge shrinkage, cracks and pore formation could be effectively reduced by adjusting the temperature and pressure. The simulation results could be used for the optimization of casting processes, thereby improved the safety performance of Melt-cast explosive. Keywords: explosive; casting; simulation; shrinkage defects; cracks;

Preventing Casting Defects of Stainless Steel Flanges Using a Water-Soaking Method

2019 ◽  
Vol 962 ◽  
pp. 189-193
Author(s):  
Pei Hsing Huang ◽  
Wei Ju Huang ◽  
Chuen Shii Chou
Keyword(s):  
Stainless Steel ◽  
High Precision ◽  
Cold Water ◽  
Flow Analysis ◽  
Casting Process ◽  
Casting Defects ◽  
Shrinkage Defects ◽  
Casting System ◽  
Simulation Results ◽  
Mold Flow

High-precision flanges are used in conjunction with O-rings, bolts, and nuts in a variety of pipe connections to prevent the leakage of harmful fluids. Flanges require good hermeticity; i.e., without pores, cavities, blow holes, or other shrinkage defects. This study employed mold flow analysis to predict where and how defects are likely to occur during the casting process. In this study, we soaked the bottom of the casting system in cold water to direct the direction of solidification from the bottom upward. Simulation results indicate that this method significantly reduces the probability of shrinkage defects in castings.

The Casting Process Design and Simulation of the Volute of 65ZGB Slurry Pump

2010 ◽  
Vol 29-32 ◽  
pp. 1574-1577 ◽  
Author(s):  
Xiao Hui Zhi ◽  
Yan Jun Han ◽  
Hai Hua Wang
Keyword(s):  
Process Parameters ◽  
Process Design ◽  
Design Principle ◽  
Casting Process ◽  
Shrinkage Defects ◽  
Simulation Results ◽  
Simulation Parameters

The casting process design and simulation of the volute of 65ZGB slurry pump were presented in this paper. The casting process design principle, process parameters, points of attention, and the simulation parameters were introduced. Huazhu CAE was used to simulate the casting process. The STL document used in Huazhu CAE was converted from the 3D moulding of the casting process using the Solidwork software. The simulation results and practical production showed that the casting process can reduce shrinkage defects of the casting.

The Numerical Simulation and Optimization in Squeeze Casting of the Air Conditioning Compressor Front Cover

2013 ◽  
Vol 803 ◽  
pp. 317-320
Author(s):  
Hai Bo Yang ◽  
Guang Liang Wang ◽  
Xue Wen Chen ◽  
De Ying Xu
Keyword(s):  
Air Conditioning ◽  
Squeeze Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Front Cover ◽  
Simulation And Optimization ◽  
Shrinkage Defects ◽  
Squeeze Casting Process ◽  
Casting Simulation Software

Using the ProCast casting simulation software to make squeeze casting process simulation and analysis of the solidification process of the air conditioning compressor front cover and predict the location of gas volumes and shrinkage defects in the filling process. When adjusted the process parameters, volumes gas defects were eliminated, but there was still shrinkage occurs in the center. When imposed a secondary pressure on the central part, shrinkage was eliminated.

Permeable Rice Husk Fibre Shell Mould System

2013 ◽  
Vol 372 ◽  
pp. 331-335 ◽  
Author(s):  
Zawati Harun ◽  
Noor Hasliza Kamarudin ◽  
Muhamad Zaini Yunos
Keyword(s):  
Rice Husk ◽  
Investment Casting ◽  
Open Porosity ◽  
Casting Process ◽  
Casting Defects ◽  
Ceramic Shell ◽  
Volatile Elements ◽  
Shell System ◽  
Mould Filling ◽  
Shell Mould

Basically, permeability of ceramic shell mould system play an important role in minimizing the casting defects in most investment casting shell. The mould has to be sufficiently permeable to obtain complete mould filling during casting process. Mould fill can be improved by increasing the open porosity that definitely will increase permeability ceramic shell mould. The elimination of rice husk volatile elements has contributed to the increment of pore structure that provides a great deal of connected pathways through the ceramic shell which directly will increase the permeability of the ceramic shell mould during casting process. Indeed, the rice husk fibers additions increase the permeability after firing by a factor 3 compared to the standard shell mould system (without fiber) that makes its an excellent alternative in producing higher permeable ceramic shell system.

Numerical Simulation and Optimization on Casting Technique of HT200 Flywheel

2010 ◽  
Vol 97-101 ◽  
pp. 2553-2557 ◽  
Author(s):  
Bin Feng He ◽  
Guo Fa Mi ◽  
Shuang Shuang He
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Casting Process ◽  
Gating System ◽  
Casting Technique ◽  
Simulation And Optimization ◽  
Casting Yield ◽  
Simulation Results

The Z-CAST software was employed to simulate the casting process of gray cast-iron flywheel. Shrinkage was predicted through analyzing the temperature field and the flow field. According to the simulation results, the gating system was improved to eliminate shrinkage, and the thin, wide ingate was shown that can reduce the shrinkage and increase casting yield.

scholarly journals Numerical simulation and optimization of casting process of copper alloy water-meter shell

2020 ◽  
Vol 12 (5) ◽  
pp. 168781402092345
Author(s):  
Kaikui Zheng ◽  
Youxi Lin ◽  
Weiping Chen ◽  
Lei Liu
Keyword(s):  
Numerical Simulation ◽  
Phase Distribution ◽  
Three Dimensional ◽  
Casting Process ◽  
Element Model ◽  
Casting Defects ◽  
Gating System ◽  
Three Dimensional Model ◽  
Simulation And Optimization ◽  
Water Meter

The water-meter shell has a complex-structured thin-walled cavity, and it can cause casting defects such as shrinkage and misrun. On the basis of structural analysis of a water-meter shell, a three-dimensional model and a finite element model of the water-meter shell were constructed using the SOLIDWORKS and ProCAST software as a modeling tool and a casting numerical simulation tool, respectively. Three processes associated with the bottom gating system without a riser, a step gating system with a preliminary riser, and a step gating system with an optimum riser were successively numerically simulated. The mold-filling sequence, temperature distribution, liquid-phase distribution during solidification, and shrinkage distribution of these three processes are discussed here. The numerical simulation results indicated that optimization of the casting process and the rational assembling of the riser led to the shrinkage volumes at the inlet position, regulating sleeve, and sealing ring of the water-meter shell decreasing from 0.68 to 0 cm3, 1.39 to 0.22 cm3, and 1.32 to 0.23 cm3, respectively. A comparison between model predictions and experimental measurements indicated that the castings produced by the optimized process had good surface quality and beautiful appearance, without casting defects, demonstrating that numerical simulation can be used as an effective tool for improving casting quality.

Numerical Simulation and Process Optimization of Aluminum Alloy Connecting Rod Based on ProCAST

2013 ◽  
Vol 712-715 ◽  
pp. 549-552
Author(s):  
Hua Feng Lu ◽  
Rong Fa Chen ◽  
Yi Hong Zhao ◽  
Long Wu ◽  
Zhi Long Li ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Casting Process ◽  
Casting Defects ◽  
Permanent Mold ◽  
Connecting Rod ◽  
Technical Requirements ◽  
Simulation Results ◽  
Die Casting Process ◽  
Filling And Solidification

The structural feature and technical indexes of 2A14 aluminum alloy connecting rod was analyzed. The pouring system of gravity die-casting process was initially designed according to the technical requirements. The gravity filling and solidification stages in the permanent mold were simulated by ProCAST. The simulation results show that the casting defects are predicted and the casting process are improved. The most possible section of crack defects are the transition part between the shaft and the connecting rod small or big end.

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