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.

Numerical Simulation of Chilled Cast Iron Camshaft in Sand Casting Process

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.

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.

Application of Numerical Simulation on Cast-Steel Axle’s V-Method Foundry

2010 ◽  
Vol 139-141 ◽  
pp. 576-579
Author(s):  
Guo Fa Mi ◽  
Li Lin Chen ◽  
Hong Yan Nan
Keyword(s):  
Numerical Simulation ◽  
Cast Steel ◽  
Three Dimensional ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Three Dimensional Model ◽  
Original Process ◽  
Shrinkage Defects ◽  
Improved Technology

The V-method foundry is an advanced casting technology compared with traditional sand casting. The Pro/E software was used to generate three-dimensional model of cast parts. The solidification process of the automotive axle casting with V-method foundry was simulated by the numerical simulation software, ViewCast. The location and scale of the shrinkage defects caused by the original process were predicted. According to the simulation results, the position of the flange round cooled too fast, which blocked the feeding passage of the round near sprue. The reason was that solidifying sequence was unperfected. The casting process was optimized by means of adding runner and chill. Progressive solidification can be obtained and the shrinkage defects can be eliminated or transferred by the improved technology. The reasonable casting process was obtained and the process has been proofed by the productive practice.

Numerical Simulation of the Casting Process with Coupled Thermal and Stress Field

2010 ◽  
Vol 29-32 ◽  
pp. 1878-1882 ◽  
Author(s):  
Jian Qiang Zhou ◽  
Fa Zhan Yang ◽  
De Sheng Li
Keyword(s):  
Numerical Simulation ◽  
Stress Field ◽  
Complex Structure ◽  
Solidification Process ◽  
Casting Process ◽  
Stress Fields ◽  
Cooling Process ◽  
Thermal Distribution ◽  
Simulation Techniques ◽  
Simulation Results

To understand the thermal distribution in a complex structure and high quality linkage casting, a mathematical model of temperature and stress field was established. Numerical simulation techniques was applied by using Procast software in the temperature and stress fields of solidification process, and the foundry defect such as old lap, misrun, shrinkage and dispersed shrinkage was predicted. The stress distribution and deformation in cooling process of casting were analyzed. The simulation results can supply a scientific foundation for foundry technology.

scholarly journals Numerical Simulation of Reoxidation Processes

2020 ◽  
Vol 328 ◽  
pp. 02007
Author(s):  
Marek Bruna ◽  
Marek Galčík
Keyword(s):  
Numerical Simulation ◽  
Liquid Metal ◽  
Aluminium Alloy ◽  
Oxide Layer ◽  
Negative Impact ◽  
Casting Process ◽  
Simulation Software ◽  
Gating System ◽  
Alloy Casting ◽  
Positive Effect

Reoxidation is one of the main problem accompanying the aluminium alloy casting process. The oxide layer created on the melt surface during reoxidation is entrained into the bulk of liquid metal and “bifilms” are created. Bifilms have negative impact on cast quality and internal homogenity of final casting. Paper aim is to clarify the reoxidation phenomenon by visualization with the aid of ProCAST numerical simulation software. Experiemtnal work deals with the design of several types of gating systems (non pressurized and naturally pressurized) with vortex elements in order to determine how these elements affect the reoxidation processes. Achieved results clearly confirmed the positive effect of the naturally pressurized gating system with vortex elements. The evaluation focuses mainly on melt velocity and amount of oxides created in gating system and in mold cavity.

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.

scholarly journals Die Casting Die Design and Process Optimization of Aluminum Alloy Gearbox Shell

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3999
Author(s):  
Mingyu Huang ◽  
Qian Zhou ◽  
Junyou Wang ◽  
Shihua Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Cooling System ◽  
Structural Characteristics ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Die Design ◽  
Production Cycle ◽  
Gating System

Taking an aluminum alloy gearbox of an automobile as an example, according to its structural characteristics, the parting surface was determined, and the initial gating system was designed by using 3D modeling software UG. Based on Magmasoft software, the numerical simulation of the filling and solidification process was carried out to determine the best gating system scheme. The cooling system and core pulling structure were designed, and the parameter design process of the aluminum alloy gearbox shell in the die-casting process was introduced. Aiming at the leakage problem of the gearbox shell in the bench and road test after assembly, the cause was found through numerical simulation and industrial CT analysis, and the problem was solved by adding high-pressure point cooling at the corresponding position of the leakage, and the correctness of the optimization was verified. It provides an effective method for the die-casting production of the transmission housing and the analysis and solution of product defects, which improves the product quality and shortens the production cycle.

Numerical Simulation of Filling and Solidification in Sand Casting by Procast

2013 ◽  
Vol 791-793 ◽  
pp. 550-553 ◽  
Author(s):  
Dong Dong Han ◽  
Cheng Jun Wang ◽  
Juan Chang ◽  
Lei Chen ◽  
Huai Bei Xie
Keyword(s):  
Numerical Simulation ◽  
Heat Dissipation ◽  
Solidification Process ◽  
Simulation Software ◽  
Sand Casting ◽  
Production Costs ◽  
Raw Material ◽  
Casting Defects ◽  
Three Dimension ◽  
Filling And Solidification

At present, pulley produced in China has been able to meet the demand of domestic and international markets. But there are many problem of the pulley industry in our country, such as too many production enterprises and the low level of export products. And as components of drive system are light weight and raw material price of pulley casting are rising, manufacturing requirements of the pulley are also more and more high. Aiming at the casting defects of pulley that enterprise current product, pulley casting blank model of common material HT250 be made by three-dimension software, numerical simulation of filling and solidification process for pulley sand casting by the casting simulation software Procast, the size and location of the various casting defects were forecasted and analyzed, reflecting the pulley filling and solidification process of the actual situation, due to the thicker pulley rim and less heat dissipation, position of shrinkage is close to the middle of rim [, a method of eliminating defects is proposed to realize sequential solidification, and thus to minimize porosity shrinkage and improve casting performance and reduce casting time and reduce production costs.

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.

Melt Mold Casting Process Optimization of Train Coupler Based on ProCAST

2018 ◽  
Vol 764 ◽  
pp. 312-322
Author(s):  
Cheng Jun Wang ◽  
Jin Yan Chen ◽  
Yu Zhe Shen
Keyword(s):  
Process Optimization ◽  
Simulation Analysis ◽  
Solidification Process ◽  
Casting Process ◽  
Process Measures ◽  
Technical Requirements ◽  
Shrinkage Defects ◽  
Mold Casting ◽  
Cae Simulation ◽  
Filling And Solidification

In order to solve production defects such as shrinkage and porosity inside a certain train coupler casting in Anhui Xinhong Machinery Co.,Ltd., the main reasons of defects are found through the process of CAE simulation analysis and physical X ray detection to determine the location and morphology of casting defects and to reflect the actual situation of coupler filling and solidification process. The main reasons are found as follows: uneven thickness of casting structure, insufficient original gating and feeding system and etc. Through the process optimization and apply multidimensional vibration, then test validation, the train coupler casting which meets the technical requirements has been successfully produced, ensuring the smooth mass production of the company. ProCAST numerical simulation results have confirmed the rationality of the proposed work in optimization process measures in reducing and eliminating the shrinkage defects.

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