Study on Data Base of Modeling Concerning Casting Phenomena in Cast-Iron-Mould Simulation Systems

2010 ◽  
Vol 457 ◽  
pp. 305-311 ◽  
Author(s):  
Zenon Ignaszak
Keyword(s):  
Cast Iron ◽  
Model Validation ◽  
Thermomechanical Properties ◽  
Experimental Simulation ◽  
Knowledge Level ◽  
Simulation Studies ◽  
Simulation Code ◽  
Iron Castings ◽  
Chunky Graphite ◽  
Simulation Systems

In the foundry processes the hard modeling based on physical-mathematical formula is burdened with simplifications resulting from both: knowledge level on description of particular phenomena and level of theirs complexity. Trends observed in modeling of foundry processes and expectations of users compared with creators’ up-grades propositions are discussed. The author presents real possibilities of efficient modeling validation considering that limits of multiphysics/multiscale modeling exist for massive cast-iron castings, including the zones infected by degenerated structure (e.g. chunky graphite, dross inclusions). The model validation demands experimental-simulation studies. In the paper also the stress grid castings made of lamellar cast-iron are presented as an example of experimental model validation including the thermomechanical properties of cast-iron and furan mould and applying special Hot Distortion (HDplus®) tests of this sand. The validation of thermo-mechanical model was carried out with the use of Comsol system and chosen foundry simulation code.

scholarly journals Validation Tests of Prediction Modules of Shrinkage Defects in Cast Iron Sample

2017 ◽  
Vol 17 (1) ◽  
pp. 57-66 ◽  
Author(s):  
J. Hajkowski ◽  
P. Roquet ◽  
M. Khamashta ◽  
E. Codina ◽  
Z. Ignaszak
Keyword(s):  
Cast Iron ◽  
Cast Alloy ◽  
Processing Parameters ◽  
Standard Test ◽  
Experimental Simulation ◽  
Simulation Code ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Iron Sample ◽  
Validation Tests

Abstract The paper presents the results of experimental-simulation tests of expansion-shrinkage phenomena occurring in cast iron castings. The tests were based on the standard test for inspecting the tendency of steel-carbon alloys to create compacted discontinuities of the pipe shrinkage type. The cast alloy was a high-silicone ductile iron of GJS - 600 - 10 grade. The validation regarding correctness of prognoses of the shrinkage defects was applied mostly to the simulation code (system) NovaFlow & Solid CV (NFS CV). The obtained results were referred to the results obtained using the Procast system (macro- and micromodel). The analysis of sensitivity of the modules responsible for predicting the shrinkage discontinuities on selected pre-processing parameters was performed, focusing mostly on critical fractions concerning the feeding flows (mass and capillary) and variation of initial temperature of the alloy in the mould and heat transfer coefficient (HTC) on the casting - chill interface.

scholarly journals Methodology of Comparative Validation of Selected Foundry Simulation Codes

2015 ◽  
Vol 15 (4) ◽  
pp. 37-44 ◽  
Author(s):  
Z. Ignaszak ◽  
P. Popielarski ◽  
J. Hajkowski ◽  
E. Codina
Keyword(s):  
Thermal Analysis ◽  
Cast Iron ◽  
Solid Fraction ◽  
Grey Cast Iron ◽  
Simulation Code ◽  
Validation Experiment ◽  
Grey Cast ◽  
Simulation Results ◽  
Simulation Systems ◽  
Comparative Validation

Abstract The validation of each simulation code used in foundry domain requires individual approach due to its specificity. This validation can by elaborated on the basis of experimental results or in particular cases by comparison the simulation results from different codes. The article concerns the influence of grey cast iron density curve and different forms of solid fraction curve Fs=f(T) on the formation of shrinkage discontinuities. Solid fraction curves applying Newtonian Thermal Analysis (NTA) were estimated. The experimental and numerical simulation tests were performed on the castings, which were made with Derivative Thermal Analysis (DerTA) standard cups. The numerical tests were realized using NovaFlow&Solid (NF&S), ProCast and Vulcan codes. In this work, the coupled influence of both curves on the dynamics of the shrinkage-expansion phenomena and on shrinkage defects prognosis in grey cast iron castings has been revealed. The final evaluation of the simulation systems usefulness should be based on validation experiment, preceded by comparing the simulation results of available systems which are proposed in given technology.

scholarly journals Management of the activity of quality assurance of cast iron castings in foundries

2021 ◽  
Vol 1781 (1) ◽  
pp. 012050
Author(s):  
A Josan ◽  
E Ardelean ◽  
M Ardelean ◽  
V Puţan
Keyword(s):  
Quality Assurance ◽  
Cast Iron ◽  
Iron Castings

scholarly journals Experimental Evidence for Metallurgical Modification Associated to Chunky Graphite in Heavy-Section Ductile Iron Castings

2012 ◽  
Vol 6 (1) ◽  
pp. 35-42 ◽  
Author(s):  
J. Lacaze ◽  
I. Asenjo ◽  
S. Méndez ◽  
J. Sertucha ◽  
P. Larrañaga ◽  
...  
Keyword(s):  
Experimental Evidence ◽  
Ductile Iron ◽  
Iron Castings ◽  
Heavy Section ◽  
Chunky Graphite

scholarly journals Influence of Technological Parameters of Furane Mixtures on Shrinkage Creation in Ductile Cast Iron Castings

2014 ◽  
Vol 59 (3) ◽  
pp. 1037-1040 ◽  
Author(s):  
I. Vasková ◽  
M. Hrubovčáková ◽  
J. Malik ◽  
Š. Eperješi
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Ductile Cast Iron ◽  
Gating System ◽  
Technological Parameters ◽  
Iron Castings ◽  
Steel Castings ◽  
The Impact ◽  
Very High ◽  
Great Development

Abstract Ductile cast iron (GS) has noticed great development in last decades and its boom has no analogue in history humankind. Ductile iron has broaden the use of castings from cast iron into areas, which where exclusively domains for steel castings. Mainly by castings, which weight is very high, is the propensity to shrinkage creation even higher. Shrinkage creation influences mainly material, construction of casting, gating system and mould. Therefore, the main realized experiment was to ascertain the influence of technological parameters of furane mixture on shrinkage creation in castings from ductile iron. Together was poured 12 testing items in 3 moulds forto determine and compare the impact of various technological parameters forms the propensity for shrinkage in the casting of LGG.

scholarly journals Opening Material as the Possibility of Elimination Veining in Foundries

2016 ◽  
Vol 16 (3) ◽  
pp. 157-161 ◽  
Author(s):  
M. Hrubovčáková ◽  
I. Vasková ◽  
M. Benková ◽  
M. Conev
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Cast Iron ◽  
Granular Material ◽  
Surface Defects ◽  
Silica Sand ◽  
Iron Castings ◽  
Thermal Dilatation

Abstract The main bulk density representation in the molding material is opening material, refractory granular material with a particle size of 0.02 mm. It forms a shell molds and cores, and therefore in addition to activating the surface of the grain is one of the most important features angularity and particle size of grains. These last two features specify the porosity and therefore the permeability of the mixture, and thermal dilatation of tension from braking dilation, the thermal conductivity of the mixture and even largely affect the strength of molds and cores, and thus the surface quality of castings. [1] Today foundries, which use the cast iron for produce of casts, are struggling with surface defects on the casts. One of these defects are veining. They can be eliminated in several ways. Veining are foundry defects, which arise as a result of tensions generated at the interface of the mold and metal. This tension also arises due to abrupt thermal expansion of silica sand and is therefore in the development of veining on the surface of casts deal primarily influences and characteristics of the filler material – opening material in the production of iron castings.

scholarly journals RESEARCH OF THE INFLUENCE OF SLOW-DOWN COOLING SPEED IN THE INTERVAL OF EUTEKTIC TRANSFORMATION ON THE STRUCTURE AND MECHANICAL PROPERTIES OF CAST IRON CASTINGS

2020 ◽  
pp. 51-55
Author(s):  
N. I. Gabelchenko ◽  
N. A. Kidalov ◽  
A. A. Belov ◽  
M. D. Bezmogorychnyy ◽  
A. I. Gabelchenko
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Cooling Rate ◽  
Quality Index ◽  
Fuel Oil ◽  
Controlled Cooling ◽  
Slowing Down ◽  
Eutectic Transformation ◽  
Iron Castings ◽  
Cooling Speed

The work is devoted to the study of the effect of slowing down the cooling rate in the interval of eutectic transformation on the structure and mechanical properties of castings from gray doeutectic iron. To slow down the cooling rate in the interval of eutectic transformation, an exothermic carbon-containing additive, fuel oil M-100, was used. It is shown that the use of controlled cooling can significantly increase the quality index of cast iron without introducing additional alloying elements into the composition of cast iron.

scholarly journals Primary Structure and Graphite Nodules in Thin-Walled High-Nickel Ductile Iron Castings

Metals ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 649
Author(s):  
Marcin Górny ◽  
Magdalena Kawalec ◽  
Gabriela Sikora ◽  
Ewa Olejnik ◽  
Hugo Lopez
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Structural Features ◽  
Eutectic Solidification ◽  
Spheroidal Graphite ◽  
Quality Factors ◽  
Iron Castings ◽  
Spheroidal Graphite Cast Iron ◽  
Graphite Cast Iron ◽  
Thin Walled

This paper considers the most important quality factors in processing spheroidal graphite cast iron; namely, primary grains and graphite nodules in thin-walled ductile iron castings (TWDI). In the present study, the effect of grain refinement (by means of Ti, Nb and Zr) and of the holding time after spheroidization and inoculation on effecting the primary grains and eutectic structure in TWDI castings was investigated. Moreover, metallographic examinations (including electron backscattering diffraction, EBSD) were carried out to reveal the macro- and micro-structural features during the primary and eutectic solidification of the cast iron. EBSD results indicate that, within a single dendritic grain, there are numerous boundaries that split the grain into numerous smaller areas. In particular, it is found that the graphite nodules are in contact with the boundaries inside the primary dendritic grain. In turn, crystallization of highly branched dendrites is observed, which seems to “push” the graphite nodules into the interdendritic regions during their growth. The present work investigates the dominant mechanism that gives rise to the primary spheroidal graphite cast iron (SGI) structure. In addition, this work shows that the melt quality is closely associated with the resultant morphology and number of austenite dendrites, graphite nodules, and matrix structure.

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