Influence of Riser Necking Ratio and Taper on the Solidification of Heavy Ingots by Numerical Simulation

2021 ◽  
Vol 871 ◽  
pp. 59-64
Author(s):  
Ya Nan Zhao ◽  
Shi Guang Ba
Keyword(s):  
Numerical Simulation ◽  
Software Package ◽  
Steel Ingot ◽  
Solidification Process ◽  
Shrinkage Porosity ◽  
Solidification Time ◽  
Secondary Porosity ◽  
Time Decrease

The effect of riser necking ratio and taper on solidification process of 96T steel ingot have been studied numerically using the software package ProCAST. The results show that the solidification time decrease with the increase of riser necking ratio, and the position of shrinkage porosity moves up and the secondary porosity presents a tendency of increase, and the inclusions on the shoulder of body ingot decreases. The riser taper has little effect on the solidification process of heavy ingots.

Influence of Mould Slenderness Ratio on the Solidification of Heavy Ingots by Numerical Simulation

2021 ◽  
Vol 871 ◽  
pp. 27-31
Author(s):  
Ya Nan Zhao
Keyword(s):  
Numerical Simulation ◽  
Software Package ◽  
Slenderness Ratio ◽  
Solidification Process ◽  
Shrinkage Porosity ◽  
Processing Factor ◽  
Bottom Part

The quality of heavy ingot normally depends on the processing factor and ingot mould type. Based on the ingot mould type only, the quality and solidification process of a 96-ton ingot moulds with different slenderness-ratios have been studied numerically using the software package ProCAST. The results show that the position of shrinkage porosity moves up and the macroporosity in the ingot center increases prominently as slenderness-ratio increasing, meanwhile, the inclusion-floating time through the middle and bottom part of ingot decreases, and A-segregation alleviates as well. The correlation between the quality and slenderness-ratio of the ingot is not a liner relationship, when the slenderness ratio is 1.4, the ingot has better quality.

The Studies on Numerical Simulation of Unidirectional Solidification Process in 23t Steel Ingot

2012 ◽  
Vol 502 ◽  
pp. 46-50
Author(s):  
Guang Wu Ao ◽  
Ming Gang Shen ◽  
Zhen Shan Zhang ◽  
Li Li Hong
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Temperature Distribution ◽  
Steel Ingot ◽  
Side Wall ◽  
Solidification Process ◽  
Unidirectional Solidification ◽  
Finite Element Software ◽  
Solidification Processes

In this paper, by using the commercial finite-element software of ProCAST, unidirectional solidification processes in 23t steel ingot were simulated. Emphasis is placed on analysis of required time for complete solidification of steel ingot and temperature distribution about ingot and side wall during the solidification process. By comparing simulation values and measured values of side wall during the solidification process, the simulated results conclusively demonstrate that our developed model is feasible and valuable.

Numerical Simulation Analysis on Shrinkage and Porosity of ZL101A Alloy Mechanism Box

2011 ◽  
Vol 704-705 ◽  
pp. 28-32
Author(s):  
Yan Jun Zhou ◽  
Ke Xing Song ◽  
Yan Min Zhang ◽  
Xiu Hua Guo
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Solidification Process ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Analysis Procedure ◽  
Liquid Distribution ◽  
Gravity Casting ◽  
Porosity Defects

The Shrinkage and porosity of ZL101A alloy mechanism box prepared by sand gravity casting process was investigated. The solidification process was simulation analysis by using InteCAST software and the original casting process was optimized based on the above simulated results. The results showed that the shrinkage and porosity defects’ position of ZL101A alloy mechanism box were accurately predicted by the analysis procedure which was from liquid distribution to shrinkage formation and then to Niyama shrinkage porosity. The shrinkage and porosity of the ZL101A alloy mechanism box prepared by optimized process were clearly reduced and the distribution of them was reasonable. Keywords: InteCAST software;ZL101A; Mechanism box; Shrinkage and porosity; Numerical simulation

Numerical Simulation of the Cooling Process of the Blast Furnace Slag Fiber

2014 ◽  
Vol 934 ◽  
pp. 223-229
Author(s):  
Wei Zhang ◽  
Xu Wang ◽  
Hong Wei Xing
Keyword(s):  
Numerical Simulation ◽  
Blast Furnace ◽  
Blast Furnace Slag ◽  
Solidification Process ◽  
Simulation Software ◽  
Diameter Ratio ◽  
Solidification Time ◽  
Temperature Fields ◽  
Cooling Process ◽  
Furnace Slag

The cooling process of the blast furnace slag fibers was simulated and calculated by the numerical simulation software. The different length-diameter ratio fibers for 100:1 and 1000:1 were chosen and the temperature fields of the fibers cooling process under the different conditions were analyzed. The results showed that the single fiber’s solidification has begun at 0.1s, the fiber forms the whole shell on its surface at 0.9s, and the center of the fiber become solid at about 1.5s. Multi-fibers cooling process is different from the single fiber and the solidification time obviously become longer. 3-fibers’ solidification performs began at about 0.1s, and the whole solidification process needs about 5s.

scholarly journals Shrinkage Porosity Criterion and Its Application to A 5.5 Ton Steel Ingot

2016 ◽  
Vol 16 (2) ◽  
pp. 27-32 ◽  
Author(s):  
C. Zhang ◽  
Y. Bao ◽  
M. Wang ◽  
L. Zhang
Keyword(s):  
Numerical Simulation ◽  
Mushy Zone ◽  
Pressure Gradient ◽  
Physical Properties ◽  
Steel Ingot ◽  
Threshold Value ◽  
Shrinkage Porosity ◽  
Diameter Ratio ◽  
Solidification Shrinkage ◽  
Ingot Solidification

Abstract In order to predict the distribution of shrinkage porosity in steel ingot efficiently and accurately, a criterion R√L and a method to obtain its threshold value were proposed. The criterion R√L was derived based on the solidification characteristics of steel ingot and pressure gradient in the mushy zone, in which the physical properties, the thermal parameters, the structure of the mushy zone and the secondary dendrite arm spacing were all taken into consideration. The threshold value of the criterion R√L was obtained with combination of numerical simulation of ingot solidification and total solidification shrinkage rate. Prediction of the shrinkage porosity in a 5.5 ton ingot of 2Cr13 steel with criterion R√L>0.21 m · °C1/2 · s−3/2 agreed well with the results of experimental sectioning. Based on this criterion, optimization of the ingot was carried out by decreasing the height-to-diameter ratio and increasing the taper, which successfully eliminated the centreline porosity and further proved the applicability of this criterion.

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.

Modeling and Numerical Simulation Research on Hollow Steel Ingot Forging Process of Heavy Cylinder Forging

2013 ◽  
Vol 712-715 ◽  
pp. 627-632
Author(s):  
Min Liu ◽  
Qing Xian Ma
Keyword(s):  
Numerical Simulation ◽  
Grain Size ◽  
Shear Zone ◽  
Grain Refinement ◽  
Steel Ingot ◽  
Effective Strain ◽  
Meridian Plane ◽  
Forging Process ◽  
Forming Load ◽  
Average Grain Size

Aiming at the disadvantages of low utilization ratio of steel ingot, uneven microstructure properties and long production period in the solid steel ingot forging process of heavy cylinder forgings such as reactor pressure vessel, a new shortened process using hollow steel ingot was proposed. By means of modeling of lead sample and DEFORM-3D numerical simulation, the deformation law and grain refinement behavior for 162 ton hollow steel ingot upsetting at different reduction ratios, pressing speeds and friction factors were investigated, and the formation rule of inner-wall defects in upsetting of hollow steel ingots with different shape factors was further analyzed. Simulation results show that the severest deformation occurs in the shear zone of meridian plane in the upsetting process of hollow steel ingot, and the average grain size in the shear zone is the smallest. As pressing speed increases, the forming load gradually increases and the deformation uniformity gets worse, while the average grain size decreases. An increase in friction factor can increase the peak value of effective strain, but it significantly reduces the deformation uniformity, increases the forming load and goes against grain refinement. Moreover, the four kinds of defects on the inner wall of steel ingot can be eliminated effectively by referring to the plotted defect control curve for hollow steel ingot during high temperature upsetting.

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