Design of metal casting mold for ADC 12 aluminium alloy with assistance of 20 kHz ultrasonic vibration

2021 ◽  
Vol 97 ◽  
pp. 19-23
Author(s):  
Hai Nguyen Thanh ◽  
◽  
Tri Pham Huu ◽  
Tung Le Thanh ◽  
Thien Vo Tan ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Lower Cost ◽  
Metal Casting ◽  
Metal Mold ◽  
Heater Power ◽  
Melting Chamber ◽  
Mold Casting ◽  
Complex Shapes ◽  
Ultrasonic Assisted ◽  
Calculated Model

Metal mold casting is widely used in industry because of higher accuracy than sand casting and lower cost than diecasting. Metal mold casting can yield products with complex shapes and adjustable cooling rate. In this work, designing and fabrication of 20 kHz ultrasonic assisted mold casting using 20Cr steel are studied. Some major components such as motor, heater power, melting chamber are selected and calculated. Model for heating and pouring the ADC 12 alloy is designed. Samples with and without ultrasonic vibration are investigated using 3D laser scan.

scholarly journals Ultrasound Effect on the Microstructure and Hardness of AlMg3 Alloy under Upsetting

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 1010
Author(s):  
Przemysław Snopiński ◽  
Tibor Donič ◽  
Tomasz Tański ◽  
Krzysztof Matus ◽  
Branislav Hadzima ◽  
...  
Keyword(s):  
Flow Stress ◽  
Ultrasonic Vibration ◽  
Light And Electron Microscopy ◽  
Load Flow ◽  
Forming Limit ◽  
Ultrasonic Vibrations ◽  
Softening Effect ◽  
Simultaneous Application ◽  
Ultrasonic Assisted ◽  
Acoustic Softening

To date, numerous investigations have shown the beneficial effect of ultrasonic vibration-assisted forming technology due to its influence on the forming load, flow stress, friction condition reduction and the increase of the metal forming limit. Although the immediate occurring force and mean stress reduction are known phenomena, the underlying effects of ultrasonic-based material softening remain an object of current research. Therefore, in this article, we investigate the effect of upsetting with and without the ultrasonic vibrations (USV) on the evolution of the microstructure, stress relaxation and hardness of the AlMg3 aluminum alloy. To understand the process physics, after the UAC (ultrasonic assisted compression), the microstructures of the samples were analyzed by light and electron microscopy, including the orientation imaging via electron backscatter diffraction. According to the test result, it is found that ultrasonic vibration can reduce flow stress during the ultrasonic-assisted compression (UAC) process for the investigated aluminum–magnesium alloy due to the acoustic softening effect. By comparing the microstructures of samples compressed with and without simultaneous application of ultrasonic vibrations, the enhanced shear banding and grain rotation were found to be responsible for grain refinement enhancement. The coupled action of the ultrasonic vibrations and plastic deformation decreased the grains of AlMg3 alloy from ~270 μm to ~1.52 μm, which has resulted in a hardness enhancement of UAC processed sample to about 117 HV.

scholarly journals HARDNESS DETERMINATION OF A CAST IRON PISTON AFTER METAL MOLD CASTING

2018 ◽  
Vol 61 (05) ◽  
pp. 201-203
Author(s):  
Denis Alexandrovich Chemezov ◽  
◽  
Timur Dmitrievich Osipov ◽  
Andrey Vasilyevich Pesenko ◽  
Tatyana Nikolaevna Komarova ◽  
...  
Keyword(s):  
Cast Iron ◽  
Metal Mold ◽  
Mold Casting

scholarly journals STRUKTUR MIKRO DAN SIFAT MEKANIS ALUMINIUM PADUAN SERI 6063 HASIL COR DARI CETAKAN LOGAM, PASIR RESIN FURAN DAN PASIR KOMOSSA

POROS ◽  
2017 ◽  
Vol 14 (1) ◽  
pp. 72 ◽  
Author(s):  
Chris Marvin ◽  
Eddy S Siradj ◽  
Sobron Yamin Lubis
Keyword(s):  
Aluminum Alloy ◽  
High Hardness ◽  
Raw Material ◽  
Sand Mold ◽  
Metal Mold ◽  
Alloy Series ◽  
Mold Casting ◽  
Furan Resin ◽  
Survey Results ◽  
High Level

Abstract: Material developments in Indonesia is already very advanced rapidly certainly need high level of violence but has a mass of light. Aluminum should be developed because it possesses a lightweight and available in the land of our country that is rich in agricultural products. As an alternative to strengthen aluminum alloy that is with Si and Mg, as well as the rapid cooling process when smelting. This study was conducted to observe the microstructure and mechanical properties of the raw material of aluminum alloy series 6063. Tests conducted with metal mold, furan resin sand mold, commossa sand mold, the cooling rate of each mold will affect the hardness of the material which can be seen microstructure with microstructural observations. The survey results revealed that the aluminum with a metal mold casting has a hardness of 54 HRB, furan resin sand has a hardness of 40 HRB, sand commossa has a hardness of 33 HRB. Metal mold has a shock force of 0,316 J/mm2, particularly a furan resin sand shock force of 0,265 J/mm2, commossa sand has a shock force of 0.206 J/mm2. Metal mold has a high hardness compared with furan resin sand rated second, while the sand was rated commossa end but increasingly harsh mean tenacity of a material value will increase. According to the test micro structure, the aluminum is brittle, the distance or the distribution of grain will be a meeting or a lot. 

Research on Milling Force in Ultrasonic Assisted End Milling of Titanium Alloy Thin-Walled Parts

2018 ◽  
Vol 764 ◽  
pp. 252-260
Author(s):  
Feng Jiao ◽  
Cheng Lin Yao ◽  
Li Zhao ◽  
Feng Qi
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
End Milling ◽  
Signal To Noise Ratio ◽  
Milling Force ◽  
Alloy Material ◽  
Ultrasonic Assisted ◽  
Thin Walled ◽  
Force Characteristics

Hard machinability of titanium alloy material and poor stiffness of thin-walled part restricted the extensive applications of titanium alloy thin-walled component in aerospace engineering. In order to increase geometric accuracy, a method of ultrasonic vibration assisted (UVA) end milling technology with workpiece vibrating in feeding direction was put forward in this paper, and the corresponding milling force characteristics in UVA milling of titanium alloy TC4 thin-walled workpiece were researched. Through theoretical analysis, the path of cutter tooth in UVA milling was analyzed. The important factors that affect milling force are obtained with the signal to noise ratio analysis. Results show that the radial cutting force in UVA milling is smaller than that in traditional milling. Cutting force fluctuate in high frequency when treated ultrasonic vibration. And the axial cutting feed is the core factor that affects the milling force. The research provides a certain reference for the precision milling of titanium alloy thin-walled parts.

Electroslag metal mold casting of glass-shaping tools

1992 ◽  
Vol 49 (4) ◽  
pp. 182-184
Author(s):  
V. N. Yashin ◽  
M. I. Dol'nikov ◽  
E. F. Solinov ◽  
V. I. Gornostaev ◽  
Yu. V. Orlovskii ◽  
...  
Keyword(s):  
Metal Mold ◽  
Mold Casting ◽  
Electroslag Metal

Research on the importance of tool–workpiece separation in ultrasonic vibration–assisted milling

2016 ◽  
Vol 231 (4) ◽  
pp. 600-607 ◽  
Author(s):  
Mohammad Mahdi Abootorabi Zarchi ◽  
Mohammad Reza Razfar ◽  
Amir Abdullah
Keyword(s):  
Experimental Data ◽  
Ultrasonic Vibration ◽  
Vibration Amplitude ◽  
Cutting Speed ◽  
Machining Processes ◽  
Friction Behavior ◽  
Ultrasonic Assisted ◽  
The Times ◽  
Analytical Relations ◽  
First Time

In recent years, various reasons for improvement of performance and efficiency in ultrasonic vibration–assisted machining processes have been reported, which were mostly descriptive and without sufficient analytical and empirical proofs. Among the different machining processes, the least amount of experimental data and analytical relations exist about ultrasonic-assisted milling. In this article, for the first time in ultrasonic-assisted milling, we have determined the times of tool–workpiece engagement and their separation from each other in each vibration cycle and then investigated the influence of vibration amplitude and cutting speed on tool–workpiece effective engagement in ultrasonic-assisted milling. Contrary to ultrasonic-assisted turning, cutting time in each vibration cycle in ultrasonic-assisted milling is different from each other. With the aid of comprehensive experiments at tool–workpiece engagement angles smaller than 90°, we have proved that the main reason for average cutting force decrease in ultrasonic-assisted milling compared with conventional milling is the separation of tool and workpiece that occurs in a portion of each vibration cycle, and other factors such as change of friction behavior have less importance. At investigated tool–workpiece engagement angles, experimental and analytical results agree with each other.

scholarly journals Interface Characteristics and Mechanical Properties of Ultrasonic-Assisted Friction Stir Lap Welded 7075-T6 Aluminium Alloy

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5335 ◽  
Author(s):  
Changshu He ◽  
Zhiqiang Zhang ◽  
Ying Li ◽  
Jingxun Wei ◽  
Menggang Zhai ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Ultrasonic Vibration ◽  
Fracture Mode ◽  
Fracture Strength ◽  
Shear Fracture ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Lap Welding ◽  
Cold Lap

In this work, friction stir lap welding (FSLW) and ultrasonic-assisted friction stir lap welding (UAFSLW) was applied to 6-mm-thick 7075-T6 alloy sheets using three welding tools with the same process parameters. The joint formation, microstructural characteristics, and mechanical properties of the resulting lap joints were then investigated. The results showed that ultrasonic vibration significantly promoted the flow of metal at the interface, enlarged the size of the stirred zone (SZ), and reduced the angle between the hook defect and the interface. During lap shear testing, the FSLW and UAFSLW joints fractured in a similar manner. The fracture modes included tensile fracture, shear fracture, and a mixture of both. Cold lap and hook defects may have served as crack-initiation zones within the joint. Under configuration A (i.e., upper sheet on the retreating side (RS)), all joints failed in the shear-fracture mode. The effective lap width (ELW) of the joint welded using tool T2 was the greatest. This resulted in a higher shear fracture strength. The maximum shear fracture strength of the UAFSLW joint was 663.1 N/mm. Under configuration B (i.e., upper sheet on the advancing side (AS)), the shear fracture strength was greatly affected by the fracture mode. The highest shear fracture strength of the UAFSLW joint, 543.7 N/mm, was welded by tool T3. Thus, under otherwise identical conditions, UAFSLW joints can withstand a greater fracture shear strength than FSLW joints, as ultrasonic vibration helps to mix the material at the interface, thus, enlarging the SZ and diminishing the cold lap defects.

The Effects of Ultrasonic Vibration in Hot Pressing for Microgrooves

2016 ◽  
Vol 861 ◽  
pp. 121-126 ◽  
Author(s):  
Jia Qing Xie ◽  
Tian Feng Zhou ◽  
Yang Liu ◽  
Tunemoto Kuriyagawa ◽  
Xi Bin Wang
Keyword(s):  
Ultrasonic Vibration ◽  
Wave Length ◽  
Fem Simulation ◽  
Maxwell Model ◽  
Mold Surface ◽  
Incomplete Filling ◽  
Surface Flaws ◽  
Generalized Maxwell Model ◽  
Ultrasonic Assisted

Microgrooves with a pitch at wave length level are increasingly needed in the optical system. Conventional, the microgroove forming accuracy is low due to the incomplete filling of the material in the cavity of microgroove mold, and surface flaws occur easily due to the adhesion of the resin material to the mold surface. In this research, the response behavior of resin material subjected to alternating stress is resolved based on Generalized Maxwell model. Finite Element Method (FEM) simulation is carried out to test the microgroove forming effects under the pressing condition without and with ultrasonic vibration. An ultrasonic assisted pressing machine is developed and used to fabricate microgrooves on methacrylic resin surface. Form accuracy and surface quality of microgrooves are confirmed to be improved by comparing the ultrasonic assisted pressing with the conventional forming.

Comparative Study and Mathematical Modeling of Machining Parameters in Ultrasonic-Assisted EDM of AISI H13 Tool Steel by the Application of Workpiece Vibration

2010 ◽  
Vol 154-155 ◽  
pp. 1604-1613
Author(s):  
Mohammad Reza Shabgard ◽  
Babak Sadizadeh ◽  
Keivan Amini ◽  
Hamid Pourziaie
Keyword(s):  
Comparative Study ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Correct Selection ◽  
Machining Parameters ◽  
Machining Performance ◽  
Ultrasonic Assisted ◽  
Aisi H13

The correct selection of the machining parameters is one of the most significant issues to take into consideration in Ultrasonic-assisted Electrical Discharge Machining (US-EDM) and EDM processes. In the present work, a study has been made to develop and extract statistical models to show the relationship between important machining performance data (material removal rate (MRR), tool wear ratio (TWR) and surface roughness Ra) and the input machining parameters (pulse current, and pulse-on time) in the EDM and US-EDM of AISI H13. The models obtained were used to analyze the effects of input parameters on machining performance. In addition, a comparative study was carried out to investigate the effect of ultrasonic vibration of the workpiece on machining performance. The results show that Ultrasonic vibration of the workpiece can significantly reduce the inactive pulses and improves the stability of process. Also US-EDM is effective in attaining a high material removal rate (MRR) in finishing regime in comparison with conventional EDM. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models can adequately explain the performance within the limits of the factors being studied.

Sign in / Sign up

Export Citation Format

Share Document