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.

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

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.

Simulation of Thixocasting Processes in Automotive Component

2005 ◽  
Vol 480-481 ◽  
pp. 361-366
Author(s):  
Antonio Forn ◽  
Sergi Menargues ◽  
Enric Martín ◽  
G.L. Chiarmetta
Keyword(s):  
Experimental Data ◽  
Numerical Simulation ◽  
Structural Parameter ◽  
Homogeneous Material ◽  
Simulation Tools ◽  
Die Filling ◽  
Real Process ◽  
Solidification Processes ◽  
Semi Solid ◽  
Filling And Solidification

Thixocasting or semi-solid casting is an alternative to the traditional casting processes. A numerical simulation of these methods is useful to define the real process. A new test concept will be presented to determine parameters, such as temperature and rates, as well as the die filling and solidification processes. The simulation tools permit us to understand better the processes, to predict and to eliminate potential defects before they take place. The studied component is a steering knuckle made of an A357 aluminium alloy. The microstructure is characterized by optical microscopy. It has been preceded to the development of a model based on the experimental data, it has been defined to the semi-solid as an homogeneous material with thixotropic properties, and the microstructure is a structural parameter. The results are compared with real tests.

Numerical Modeling on Sand Casting Process of a Wind Turbine Part

2011 ◽  
Vol 121-126 ◽  
pp. 1367-1371 ◽  
Author(s):  
Qing Ming Chang ◽  
Yin Kai Yang ◽  
Xia Chen ◽  
Chang Jun Chen ◽  
Si Qian Bao
Keyword(s):  
Numerical Simulation ◽  
Numerical Modeling ◽  
Wind Turbine ◽  
Research Work ◽  
Casting Process ◽  
Mold Filling ◽  
Sand Casting ◽  
Shrinkage Cavity ◽  
Pouring Temperature ◽  
Filling And Solidification

In this research work, ProCAST software is employed to study the sand casting process of a box-type part for wind turbine. The casting part is big in size, non-uniform in wall thickness, and heavy in some local positions. Shrinkage cavity and porosity are very likely to from at these locations. By numerical simulation, the influence of the parameters such as pouring temperature, chills, riser on mold filling and solidification is analyzed. Simulation researches reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced.

Process Optimization of Large Turbine Blade Casting Base on Numerical Simulation

2009 ◽  
Vol 16-19 ◽  
pp. 535-539
Author(s):  
Deng Yu Gai ◽  
Yu Zhao Chu ◽  
Qing Fen Li ◽  
Qun Xia Li
Keyword(s):  
Numerical Simulation ◽  
Velocity Field ◽  
Stress Field ◽  
Turbine Blade ◽  
Process Optimization ◽  
Temperature Fields ◽  
Solidification Processes ◽  
Velocity And Temperature Fields ◽  
Blade Casting ◽  
Filling And Solidification

3-D velocity and temperature fields of mold filling and solidification processes of large turbine blade casting were simulated. It indicated that the velocity field of upright casting is faster and steadier than lying casting. The deformation was predicted and the rule of deformation was reflected by analyzing stress field during solidification of upright casting. The casting processes were optimized, and then applied to produce castings.

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.

Foundry Technique Designing of the Large Scale Thin-Section Casting

2011 ◽  
Vol 121-126 ◽  
pp. 325-329
Author(s):  
Bin Feng He
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Thin Section ◽  
Large Scale ◽  
Liquid Fraction ◽  
Simulation Software ◽  
Pressure Casting ◽  
Counter Pressure ◽  
Shrinkage Defects ◽  
Filling And Solidification

The FDM numerical simulation software View Cast system was employed to the counter-pressure casting of aluminum alloy large-scale thin-section casting. By analyzing the mold filling and solidification, the distribution of liquid fraction, temperature field were studied. The potential shrinkage defects were predicted to be formed at the top of the casting. A solution towards reducing such defects has been presented. The feeding capacity of the riser was improved. Analysis on the shrinkage proved that the improved riser is an effective method for reduction of defects.

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.

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