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.

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 Experimental Investigation and Optimization of the Semisolid Multicavity Squeeze Casting Process for Wrought Aluminum Alloy Scroll

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5278
Author(s):  
Yi Guo ◽  
Yongfei Wang ◽  
Shengdun Zhao
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Squeeze Casting ◽  
Shrinkage Porosity ◽  
Optimal Process ◽  
Squeeze Pressure ◽  
Wrought Aluminum

Scroll compressors are popularly applied in air-conditioning systems. The conventional fabrication process causes gas and shrinkage porosity in the scroll. In this paper, the electromagnetic stirring (EMS)-based semisolid multicavity squeeze casting (SMSC) process is proposed for effectively manufacturing wrought aluminum alloy scrolls. Insulation temperature, squeeze pressure, and the treatment of the micromorphology and mechanical properties of the scroll were investigated experimentally. It was found that reducing the insulation temperature can decrease the grain size, increase the shape factor, and improve mechanical properties. The minimum grain size was found as 111 ± 3 μm at the insulation temperature of 595 °C. The maximum tensile strength, yield strength, and hardness were observed as 386 ± 8 MPa, 228 ± 5 MPa, and 117 ± 5 HV, respectively, at the squeeze pressure of 100 MPa. The tensile strength and hardness of the scroll could be improved, and the elongation was reduced by the T6 heat treatment. The optimal process parameters are recommended at an insulation temperature in the range of 595–600 °C and a squeeze pressure of 100 MPa. Under the optimal process parameters, scroll casting was completely filled, and there was no obvious shrinkage defect observed inside. Its microstructure is composed of fine and spherical grains.

The Defects Analysis and Numerical Simulation of Automobile Brake Hydro Cylinder in Permanent Casting

2011 ◽  
Vol 704-705 ◽  
pp. 82-87
Author(s):  
Lei Rao ◽  
Lian Bing Zhu ◽  
Xiao Long Li ◽  
Qi Yao Hu
Keyword(s):  
Numerical Simulation ◽  
Shrinkage Cavity ◽  
Work Piece ◽  
Braking System ◽  
Casting Quality ◽  
Solidification Processes ◽  
Gas Entrapment ◽  
Defects Analysis ◽  
Filling And Solidification ◽  
Advanced Computer

Brake hydro cylinder is the key part of automobile hydraulic braking system, which usually works under high pressure condition. So, high safety factor of it is required to avoid accident. There are many kinds of casting defects such as shrinkage cavity, gas entrapment and slag enclosure are formed in the mold filling and solidification processes, which contribute to final casting performance. Based on the mathematical models of molding filling and solidification processes, the numerical simulation has been done. In the meanwhile, the defects forming reasons have been analyzed. According to the simulation results, two types of improved schemes have been analyzed and practiced respectively, and its work piece defects were reduced largely. It is an effective way to improve the casting quality by advanced computer technology.

scholarly journals Prediction of Shrinkage Porosity in Femoral Stem of Titanium Investment Casting

2016 ◽  
Vol 16 (4) ◽  
pp. 157-162 ◽  
Author(s):  
◽  
Muslim Mahardika ◽  
A. Syamsudin ◽  
Keyword(s):  
System Design ◽  
Investment Casting ◽  
Pure Titanium ◽  
Femoral Stem ◽  
Solidification Process ◽  
Shrinkage Porosity ◽  
Commercially Pure Titanium ◽  
Gating System ◽  
Cross Section Area ◽  
System Designs

Abstract Design of gating system is an important factor in obtaining defect-free casting. One of the casting defects is a porosity caused by internal shrinkage in solidification process. Prediction of the internal shrinkage porosity in the femoral stem of commercially pure titanium (CP-Ti) is investigated based on the gating system design. The objective of this research is to get the best gating system between three gating system designs. Three gating system designs of the femoral stem were simulated in an investment casting method. The internal shrinkage porosity occurs on the largest part and near the ingate of the femoral stem. The gating system design that has ingates cross section area: 78.5; 157; and 128.5 mm2 has the least of the internal shrinkage porosity. This design has the most uniform solidification in the entire of the femoral stem. An experiment is conducted to validate the simulation data. The results of internal shrinkage porosity in the three gating system designs in the simulation were compared with the experiment. Based on the comparison, the trend of internal shrinkage porosity at the three gating system designs in the simulation agrees with the experiment. The results of this study will aid in the elimination of casting defect.

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.

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.

Numerical Simulation of Filling and Solidification Process for Low Superheat Billet Continuous Casting

2011 ◽  
Vol 189-193 ◽  
pp. 3899-3903
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang ◽  
Jin Bao Lin ◽  
Jun Ting Zhang
Keyword(s):  
Continuous Casting ◽  
Liquid Steel ◽  
Solidification Rate ◽  
Submerged Entry Nozzle ◽  
Solidification Process ◽  
Billet Continuous Casting ◽  
Solidification Processes ◽  
Filling And Solidification ◽  
Low Superheat

In view of the process of flowing steel before the establishment of strip casting, the low superheat forced pouring continuous casting technology, i.e. the molten steel is cooled by the rotating cooling rollers, then it is forced to flow into mold, has been put forward in order to reduce superheat of liquid steel, enhance the efficiency of heat transfer and improve inner structure of billet. The filling and solidification processes of low superheat casting and submerged entry nozzle(SEN) casting are numerical simulated using fluid dynamics software. It is gained that velocity distributing diagrams, temperature distributing diagrams and solidification distribution diagrams at different time in the filling process. Influences of twin-roller cooling pouring on velocity field, temperature field and solidification are analyzed. The results show that the superheat of liquid steel is decreased and the solidification rate of liquid steel is increased by low superheat casting of twin-roller cooling process, which is favorable to improving the quality of billet and enhancing pull speed.

Analysis and Optimization on the Gating System of Aluminum Alloy Piston in Casting

2011 ◽  
Vol 80-81 ◽  
pp. 32-35 ◽  
Author(s):  
Yin Fang Jiang ◽  
Yi He ◽  
Yu Zhong He ◽  
Xiao Ming Qian ◽  
Yu Huang
Keyword(s):  
Process Parameters ◽  
Shrinkage Porosity ◽  
Opening Angle ◽  
Gating System ◽  
Ring Groove ◽  
Element Analysis ◽  
Production Practice ◽  
Porosity Defects ◽  
Casting Yield ◽  
Open Cycle

Shrinkage porosity defects occurring in ring groove underside the pin hole of aluminum piston are strongly influenced by the time-varying temperature profiles inside the solidifying casting. By adopting the finite element analysis software PROCAST and combining with production practice, the gating system which has open-cycle ring feeding channel in the bottom of the piston was compared with conventional techniques; the influence of opening angle of ring feeding channel and different process parameters on shrinkage distribution was researched. The results show the gating system with open-cycle ring feeding channel can satisfy progressive solidification and effectively eliminate the shrinkage in ring groove underside piston pin hole, and can greatly reduce the riser size and improve casting yield; the opening angle influences shrinkage distribution and can be adjusted to achieve effective feeding; shrinkage size is influenced by pouring temperature and casting speed which have less effect on shrinkage distribution. The system of ring feeding channel is adopted, the opening angle and process parameters are adjusted, all which can effectively eliminate shrinkage in the bottom of the piston, improve casting yield and process rate.

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