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.

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.

Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting

2011 ◽  
Vol 121-126 ◽  
pp. 254-258
Author(s):  
Bai Yang Lou ◽  
Fang Li Liu ◽  
Kang Chun Luo
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Casting Defects ◽  
Casting Simulation ◽  
Pressure Die Casting ◽  
Filling And Solidification

The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

Numerical Simulation Software of Casting Process used for Computer Aided Instruction

2011 ◽  
Vol 399-401 ◽  
pp. 13-16
Author(s):  
Jian Min Zeng ◽  
Jie Liang ◽  
Zhi Liu Hu ◽  
Ping Chen ◽  
Li Hua Liang
Keyword(s):  
Numerical Simulation ◽  
Casting Process ◽  
Simulation Software ◽  
Computer Aided Instruction ◽  
Casting System ◽  
Computer Aided ◽  
Solidification Processes ◽  
Software Utility ◽  
Casting Design ◽  
Filling And Solidification

Simulation software is an essential tool for today‘s engineers. Its application enables castings to be designed with predicting the final results prior to they are produced. Thus, the simulation plays significant role in casting production. If a realistic calculation of the mold filling and solidification processes can be made it is possible to predict casting defects caused by casting system and/or casting design. In order to understand the changes occurring during solidification of casting, numerical simulation has been used in our classroom teachings for postgraduates. The software structures, mathematical principles, software utility, functions and output criteria are introduced in this paper to demonstrate that computer aided instruction is of Intuitive, attractive and can be used in classroom before the real experiments as assistant means to help postgraduates to understand what is casting and what is solidification

Numerical Simulation of Mold Filling and Solidification Process for Beam Blank Continuous Casting

2012 ◽  
Vol 538-541 ◽  
pp. 506-509
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang
Keyword(s):  
Velocity Field ◽  
Continuous Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Filling Process ◽  
Continuous Casting Mold ◽  
Commercial Code ◽  
Solidification Speed ◽  
Filling And Solidification

Mold filling and solidification of molten steel for 750mm×450mm×300mm continuous casting mold of single SEN and double SEN are simulated by using CFD commercial code Flow-3d. The distributing diagrams of velocity field and temperature field and the location and shape diagrams of free-surface during mold filling process are obtained. Influences of single SEN model and double SEN model on velocity field and solidification are analyzed. It is found that double SEN model can lighten circumfluence intensity at the upper of mold, quicken solidification speed of steel liquid in the mold, which is favorable to improving the quality of billet and enhancing pull speed.

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.

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.

Study on Pressure Variations in the Mold of Magnesium Alloy Die Castings

2007 ◽  
Vol 353-358 ◽  
pp. 1614-1616
Author(s):  
Yan Gai Liu ◽  
Zhao Hui Huang ◽  
Hao Ding ◽  
Ming Hao Fang ◽  
Shou Mei Xiong
Keyword(s):  
Magnesium Alloy ◽  
Real Time ◽  
Time Pressure ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Mold Filling ◽  
Die Casting Process ◽  
Die Castings ◽  
Filling And Solidification

High pressure die casting is the most common method in making magnesium alloys for both auto parts and 3C products. Pressure variations in the mold during mold filling and solidification process have direct influences on the quality and properties of die castings. In this paper, a cylinder head cover was produced to experimentally study pressure variations in the mold during magnesium alloy die-casting process in real time for the first time. Pressure varies at different positions in the mold during die casting process. This study indicates that mold filling and solidification process of magnesium alloy die castings can be described by pressure curves obtained by pressure measurement at different test positions in the cavity in real time.

Design and Simulation Optimization of Casting Process for Aluminum Alloy Engine Cylinder Head

2014 ◽  
Vol 494-495 ◽  
pp. 593-597
Author(s):  
Xiu Xiu Pan ◽  
Yi Yang ◽  
Gang Yang ◽  
De Qiang Yin ◽  
Yu Zhou
Keyword(s):  
Cylinder Head ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Production Cycle ◽  
Modeling Process ◽  
Engine Cylinder ◽  
Filling And Solidification ◽  
Trial Cost

The liquid metal filling and solidification process of aluminum engine cylinder head in different gating system during casting process was simulated by casting simulation software MAGMAsoft. The simulation results showed that the best pouring process contains the bottom note type casting and the placement of combustion chamber side, so that we could obtain a simple modeling process, and significantly shorten the trial production cycle, as well as the trial cost of the piston, and improve the quality of the cylinder head.

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.

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