Numerical Simulation on Filling Optimization of Copper Rotor for High Efficient Electric Motors in Die Casting Process

2017 ◽  
Vol 898 ◽  
pp. 1163-1170
Author(s):  
Ya Nan Wu ◽  
Guo Jie Huang ◽  
Lei Cheng ◽  
Daniel Liang ◽  
Wei Xiao
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Casting Process ◽  
Filling Process ◽  
Technological Parameters ◽  
Filling Time ◽  
High Efficient ◽  
Simulation Results ◽  
Die Casting Process ◽  
Cold Chamber

The parametric optimization of process parameter in cold chamber die casting for an industrial component (copper motor rotors) was analyzed. The filling process was successfully simulated based on software FLOW-3D. The distribution of gas entrapment, temperature field and surface defect during the mold filling process were discussed in details. The numerical results showed that the pouring velocity had the most significant influence on the filling time, followed by the filling temperature and the die temperature. As for the filling properties, the effect of the pouring temperature was dominant. From the simulation results, the places of defect in the copper rotor were forecasted, and the reasons of the defect were well explained. Thus, the technological parameters could be improved in numerical simulation, and the simulation results would be further validated in practice.

Numerical Simulation on the Filling Process of Rheological Die Casting and Forming Defects Analysis

2012 ◽  
Vol 192-193 ◽  
pp. 293-298 ◽  
Author(s):  
Fan Zhang ◽  
Nan Nan Song ◽  
Jun Zhang ◽  
Yong Lin Kang ◽  
Qiang Zhu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Solid Particles ◽  
Filling Process ◽  
Die Casting Process ◽  
Defects Analysis ◽  
Semi Solid ◽  
Forming Defects

According to semi-solid slurry rheological behavior, an apparent viscosity model of A356 alloy developed based on the Carreau model was established to simulate filling process of rheo-diecasting about automobile shock absorber parts and to compare with conventional liquid filling process. Numerical simulation results showed that the filling process of rheo-diecasting was smooth but difficult to splash, which reduced the tendency of the alloy oxidation and inclusion. Meanwhile, a certain percentage of the primary solid particles precipitated before filling and solidification shrinkage of semi-solid slurry were small. This benefited to reduce or eliminate shrinkage defects of the castings. Compared with conventional liquid die casting process, rheo-diecasting process had unique advantages in reducing the internal defects and improving mechanical properties of castings.

scholarly journals Experiments on the Model Testing of the 2nd Phase of Die Casting Process Compared with the Results of Numerical Simulation

2015 ◽  
Vol 15 (4) ◽  
pp. 21-24
Author(s):  
R. Dańko ◽  
J. Dańko ◽  
J. Stojek
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Casting Process ◽  
Inlet System ◽  
Inlet Velocity ◽  
Model Liquid ◽  
Volumetric Rate ◽  
Calculation Module ◽  
Die Casting Process ◽  
Cold Chamber

Abstract Experiments of filling the model moulds cavity of various inner shapes inserted in rectangular cavity of the casting die (dimensions: 280 mm (height) × 190 mm (width) × 10 mm (depth) by applying model liquids of various density and viscosity are presented in the paper. Influence of die venting as well as inlet system area and inlet velocity on the volumetric rate of filling of the model liquid - achieved by means of filming the process in the system of a cold-chamber casting die was tested. Experiments compared with the results of simulation performed by means of the calculation module Novacast (Novaflow&Solid) for the selected various casting conditions - are also presented in the paper.

Numerical Simulation of Semi-Solid Die Casting Process of Magnesium Alloy

2011 ◽  
Vol 474-476 ◽  
pp. 255-259 ◽  
Author(s):  
Ya Ping Hu ◽  
Yong Hu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Flow Characteristics ◽  
Casting Process ◽  
Die Design ◽  
Filling Process ◽  
Die Filling ◽  
Gas Cavity ◽  
Die Casting Process ◽  
Semi Solid

Numerical simulation can be used to predict die filling, and hence to optimize the die design. In the study, the flow characteristics of liquid filling comparing with those of semi-solid filling were analyzed. The results indicated that the liquid filling turned out to be turbulent, while the semi-sold filling had laminar flow characteristics which could reduce the foundry defects such as gas cavity and oxidation mixture. The distribution of pressure reduced gradually in the filling direction during semi-solid filling process which would generate back pressure that was favorable for filling process.

Shell Die-Casting and its Process Based on Numerical Simulation

2011 ◽  
Vol 233-235 ◽  
pp. 1167-1170 ◽  
Author(s):  
Yao Huang ◽  
Yue Dong ◽  
Yong Huang
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Casting Process ◽  
Velocity Fields ◽  
Shrinkage Cavity ◽  
Variation Trend ◽  
Casting Technology ◽  
Simulation Results ◽  
Die Casting Process ◽  
Temperature And Velocity Fields

In this paper, the distribution and variation trend of temperature and velocity fields were obtained by numerical simulation of the casting process of shell die casting. According to the results of the numerical simulation, the die casting technology was optimized. The sound castings were produced. It was verified that shrinkage cavity and porosity could be reduced by increasing injected pressure and decreasing pouring and mould temperatures. The reliability of numerical simulation of die casting process was proved. In addition, the qualified products were obtained on the basis of the optimized die-casting parameters from the simulation results.

Similarity Analysis Applied to the Die Casting Process

1989 ◽  
Vol 111 (4) ◽  
pp. 393-398 ◽  
Author(s):  
E. R. G. Eckert
Keyword(s):  
Liquid Metal ◽  
Large Scale ◽  
Die Casting ◽  
Casting Process ◽  
Injection Velocity ◽  
Similarity Analysis ◽  
Filling Process ◽  
Model Experiments ◽  
Filling Time ◽  
Die Casting Process

Detailed studies of the filling process of the die with liquid metal and the solidification are necessary to put this technology on a firm scientific basis. An experimental study of the fluid flow, heat transfer, and solidification encounters, however, enormous difficulties. It is extremely fast [in order of milliseconds], the small scale of the die makes local measurements difficult, and the temperature range and the nature of the liquid metal does not lend itself readily to experimentation. This paper explores whether similarity analysis is useful for the design of model experiments which reduce these difficulties and which reproduce the actual occurrence faithfully. The study is carried out in two steps. During the initial period, the whole cavity of the die is available for the fluid. Reynolds and Weber numbers which have to have the same value for the model experiment and for the die casting process permit the use of any fluid and of a large scale model which decreases the injection velocity and increases the filling time. During the later period of the filling process the cavity available for the liquid is reduced by the solidified metal. The energy conservation equation results in two more dimensionless numbers, the Prandtl and Jakob numbers which prescribe that model experiments have now to use a liquid metal but use of a metal with a low melting point and of a large scale decrease again the required injection velocity and increase the filling time by orders of magnitude, conditions beneficial for detailed and accurate experiments.

Semisolid Die-Casting Process of Mg-20Al-0.8Zn Magnesium Alloy

2011 ◽  
Vol 306-307 ◽  
pp. 539-543
Author(s):  
Feng Yun Yan ◽  
Xiao Feng Huang ◽  
Bo Li ◽  
Ying Ma
Keyword(s):  
Tensile Strength ◽  
Die Casting ◽  
Injection Pressure ◽  
Casting Process ◽  
Elongation Rate ◽  
Isothermal Heat Treatment ◽  
Technological Parameters ◽  
Injection Speed ◽  
Die Casting Process ◽  
Spherical Grains

Based on microstructure evolution of Mg-20Al-0.8Zn magnesium alloys realized by semisolid isothermal heat-treatment (SSIT), we obtained the non-dendrite or spherical grains microstructure under the suitable technological parameters that isothermal temperature is 495 °C and holding time is 120 min. With the help of special experimental equipment, the semisolid die-casting process has been studied and the specimens have been analyzed. The effects of different parameters as injection speed and pressure on tensile strength, elongation rate, hardness, etc have been investigated. The results indicate that tensile strength was improved along with increasing injection speed and pressure. However, excessive speed will involve gas, which formed defects and reduced the mechanical properties. When the injection pressure is 40MPa and injection speed is 4m/s, the tensile strength and elongation rate can reach maximal 220MPa and 5.63% respectively. Its fracture mechanism was intercrystalline cracking.

Application of Numerical Simulation Technology on the Design of Camera Shell during Die Casting Process

2007 ◽  
Vol 26-28 ◽  
pp. 1041-1044
Author(s):  
Hong Yan ◽  
Zhi Hu ◽  
Ti Shuan Suan
Keyword(s):  
Numerical Simulation ◽  
Material Science ◽  
Die Casting ◽  
Casting Process ◽  
Practical Result ◽  
Die Casting Process ◽  
Computer Numerical Simulation ◽  
The Cost ◽  
Pressure Die Casting

The technology of computer numerical simulation on casting process is an important frontal field of material science and technology. The numerical simulations of camera shell in the pressure die casting process were carried out. The distributions of temperature and solidification time in the filling process were obtained. Based on the simulated results and the Niyama criterion G/ R , the positions of slack were predicted, which were agreement with the practical result. Consequently, an improved scheme was presented, in which the workpiece defects were obviously reduced. So it’s significant for the application of numerical simulation on improving the quality of the casting, shortening the period of producing, reducing the cost and guiding the engineer for taking reasonable method to optimize the technological design.

Sign in / Sign up

Export Citation Format

Share Document