scholarly journals CFD Optimization Method to Design Foam Residue Traps for Full Mold Casting

2021 ◽  
Author(s):  
Yuto Takagi ◽  
Masahiro Inagaki ◽  
Ken’ichi Yano
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Optimization Method ◽  
Post Treatment ◽  
Metal Casting ◽  
Mold Casting ◽  
Casting Design ◽  
Cfd Optimization ◽  
Product Part

Full mold casting is a casting process in which a mold made of wood or metal is substituted for a styrofoam model. This metal casting process is advantageous for the production of large-sized castings because it uses a foamed model. However, this unique process of melting a foamed model causes a problem which is the foamed model remains dissolved in the casting. This is called foam residue defect and is specific to full mold casting. In this study, we propose a new casting design called a residue trap to reduce these residue defects. This residue trap collects the residue of foam models included in the molten metal, which tends to be generated when the temperature of the molten metal becomes low by being attached to the product part in the same way to overflows. We also optimized the shape of the residue trap in terms of easing of post-treatment and increasing efficiency of collecting foam residue. Eventually, the effectiveness of the residue trap was verified by actual full mold casting experiments.

scholarly journals An analysis of brass casting parameter process using sand casting mold

2019 ◽  
Author(s):  
M Nasrul Kamal
Keyword(s):  
Liquid Metal ◽  
Molten Metal ◽  
Casting Process ◽  
Sand Casting ◽  
Metal Casting ◽  
Liquid Pressure ◽  
Casting Mold ◽  
Casting Parameter

This research tried to analyze the existing casting process ofganto recycled brass by varying the liquid pressure parameters ofdifferent induction metals, followed by the pouring of liquid metal intothe mold. The method used in this research was descriptive qualitativewith aesthetic analysis. As a result, metal casting can be defined as theprocess of molten metal, poured into a mold, then allowed to be cooland freeze. In conclusion, Ganto is one of the objects of brass castingthat continues to produce the brass handicrafts in Jorong Kapalo Koto,especially the production center of Zikri ganto.

scholarly journals Local microwave heating of sand molds as a means to overcome design limitations in sand mold casting

2014 ◽  
Vol 12 ◽  
pp. 21-28 ◽  
Author(s):  
O. Wiedenmann ◽  
R. Ramakrishnan ◽  
P. Saal ◽  
E. Kılıç ◽  
U. Siart ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Microwave Heating ◽  
Casting Process ◽  
Sand Mold ◽  
Metal Casting ◽  
Temperature Dependent ◽  
Selective Heating ◽  
Thermodynamic Simulations ◽  
Mold Casting ◽  
Absorbing Materials

Abstract. Microwave induced selective heating outmatches conventional mold heating by convective heat transfer in means of energy efficiency and cycle time. Moreover, it provides the opportunity of a local manipulation of solidification and cooling processes within the sand casting mold. In this paper, we investigate the suitability of different highly absorbing materials to indirectly heat up the mostly microwave transparent sand mold. The temperature-dependent permittivity of the involved materials is determined by resonator experiments and subsequently used to simulate the electromagnetic field and the thermodynamic response of the sand mold prior to a metal casting process. Experimental results are presented and compared with the outcome of the coupled electromagnetic-thermodynamic simulations and the influence of local microwave heating on the solidification and cooling of the cast is studied.

Automatic Control of Molten Metal Flow for Improving Casting Performance

2011 ◽  
Vol 693 ◽  
pp. 179-184
Author(s):  
Thomas Jarlsmark ◽  
Jan Strömbeck ◽  
Mikael Terner ◽  
Jerry Wilkins
Keyword(s):  
Molten Metal ◽  
Metal Flow ◽  
Casting Process ◽  
Direct Chill ◽  
Level Control ◽  
Level Measurement ◽  
Cost Efficient ◽  
Molten Metal Flow ◽  
Automatic Level ◽  
Rolling Ingot

The ways to gain better quality and higher casting performance is an urgent topic among aluminium producers today. This issue is also often on the agenda at conferences like this and the subjects and technologies to achieve this varies. Controlling the molten metal flow by maintaining predefined levels or level patterns is one of many powerful tools to reach this goal. Precimeter Control specializes in applications for non-ferrous molten metal level measurement and molten metal flow control. By integration, or retrofitting, any new or existing casting line can easily be automatically controlled and gain improved casting performance in a cost efficient way. This paper will focus on the main benefits from automatic level control and how some plants have achieved improvements in their casting process of DC (Direct Chill) slab (or rolling ingot) casting after implementing such technology.

REDESIGN N METAL CASTING TOOLS USING ANTHROPOMETRY AND QFD

2019 ◽  
Vol 1 (2) ◽  
pp. 16-23
Author(s):  
Andung Jati Nugroho ◽  
Erma Kusumaningsih ◽  
Ferida Yuamita ◽  
Aldi Yoga Pradana
Keyword(s):  
Liquid Metal ◽  
Quality Function Deployment ◽  
Combustion Process ◽  
Casting Process ◽  
Metal Casting ◽  
White Cement ◽  
Casting Tool ◽  
Design Idea ◽  
Body Map ◽  
Design Ideas

The case in the metal casting process is when the metal is melted and then poured into a liquid metal reservoir and then poured into a pouring tool and then poured into a mold. In the process of pouring into the mold is still using manual equipment, namely by using wood which ends have a container such as a bucket ( bucket)) made of a mixture of white cement, brick fire sand and clay and the metal liquid pouring tool has a length of 1.5 cm, a weight of 5 kg with a diameter of 15 cm and a height of a container for liquid metal 20 cm does not include the load. If the pouring device filling with liquid metal, then the weight reaches ± 20 kg, with a weight of ± 20 kg the worker must pour the liquid continuously into the mold and at least each worker must go back and forth 6 times pouring metal liquid into a mold in a single combustion process. Based on the nordic body map questionnaire data as many as 8 workers felt pain in the shoulder and arm because the burden was born, resulting in workers often feel pain in the muscles of the arms and back. Because the wooden handle used to pour metal liquid is too slippery (exposed to sweat), so there is a need for improvement in activities. From the results of the above observations, it is necessary to design ideas for new work facilities. It expects to affect the improvements related to the position of the hand in the process of pouring liquid into the mold. Then the design idea needs to be done in the form of a casting tool that has been modified and can be used according to user needs and can be said to be ergonomic, safe, and comfortable. The method used in designing castings is quality function deployment and anthropometric techniques.

scholarly journals THE CHARACTERISTICS OF LAMPUNG LOCAL SAND AS CASTING SAND IN THE METAL CASTING PROCESS

2019 ◽  
Vol 30 (1) ◽  
pp. 10
Author(s):  
Yusup Hendronursito ◽  
David Candra Birawidha ◽  
Kusno Isnugroho ◽  
Fathan Bahfie ◽  
Wulanda Yurista Persatika ◽  
...  
Keyword(s):  
Casting Process ◽  
Metal Casting ◽  
Casting Sand

scholarly journals Pre-Detecting Method for Molten Metal Leakage in Casting Process by Using Air Leakage Through Molds

DENKI-SEIKO ◽  
2008 ◽  
Vol 79 (4) ◽  
pp. 329-335
Author(s):  
Naoki Fuse ◽  
Kenichi Tate ◽  
Atsushi Komori
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Air Leakage ◽  
Detecting Method

Melt Mold Casting Process Optimization of Train Coupler Based on ProCAST

2018 ◽  
Vol 764 ◽  
pp. 312-322
Author(s):  
Cheng Jun Wang ◽  
Jin Yan Chen ◽  
Yu Zhe Shen
Keyword(s):  
Process Optimization ◽  
Simulation Analysis ◽  
Solidification Process ◽  
Casting Process ◽  
Process Measures ◽  
Technical Requirements ◽  
Shrinkage Defects ◽  
Mold Casting ◽  
Cae Simulation ◽  
Filling And Solidification

In order to solve production defects such as shrinkage and porosity inside a certain train coupler casting in Anhui Xinhong Machinery Co.,Ltd., the main reasons of defects are found through the process of CAE simulation analysis and physical X ray detection to determine the location and morphology of casting defects and to reflect the actual situation of coupler filling and solidification process. The main reasons are found as follows: uneven thickness of casting structure, insufficient original gating and feeding system and etc. Through the process optimization and apply multidimensional vibration, then test validation, the train coupler casting which meets the technical requirements has been successfully produced, ensuring the smooth mass production of the company. ProCAST numerical simulation results have confirmed the rationality of the proposed work in optimization process measures in reducing and eliminating the shrinkage defects.

Properties and CA4GE-Engine Test of TiAl-Based Alloy Valves by Permanent Mold Casting

2010 ◽  
Vol 139-141 ◽  
pp. 557-560
Author(s):  
Wen Bin Sheng ◽  
Chun Xue Ma ◽  
Wan Li Gu
Keyword(s):  
Tial Alloy ◽  
Centrifugal Casting ◽  
Casting Process ◽  
Vacuum Arc ◽  
Permanent Mold ◽  
Casting Method ◽  
Arc Melting ◽  
Vacuum Arc Melting ◽  
Mold Casting ◽  
Induction Skull Melting

TiAl-based alloy valves were manufactured by combining charges compressed /vacuum arc melting (VA)/ induction skull melting (ISM) procedure with permanent mold centrifugal casting method. Microstructures, compositions and mechanical properties of as-cast and hot isostatical pressed (HIPed) valves are detected. Results show that the permanent mold centrifugal casting process obviously refines the size of grain in TiAl alloy and the tensile strength of as-cast and HIPed valves are 550MPa and 580MPa at 20°C, 370MPa and 470MPa at 815°C, respectively. As-cast specimens show ~0% elongation at 20°C and 1~2% at 815°C, while HIPed ones show an elongation of 1~2% at room temperature and about 10% at 815°C. Furthermore, a 200-hour test was carried out with CA4GE-engine, which demonstrated the possibility of as-cast TiAl alloy valves for the substitution of present steel ones.

Numerical Simulation of Molten Metal-Polymeric Foam Interface Velocity During Lost Foam Casting

2001 ◽  
Author(s):  
Sayavur I. Bakhtiyarov ◽  
Ruel A. Overfelt
Keyword(s):  
Molten Metal ◽  
Flow Model ◽  
Interface Velocity ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Foam Material ◽  
Polymeric Foam ◽  
Gaseous Products ◽  
3D Software ◽  
Lost Foam

Abstract A novel multiphase flow model is presented for describing the pyrolisis of polymeric foam material in a lost foam casting process. FLOW-3D software (Flow Science, Inc.) has been used to simulate liquid metal filling dynamics and the molten metal-polymeric foam interface velocity in foam patterns of rectangular shape. The effect of the degradation gaseous products on the molten metal-polymeric foam interface velocity was taken into consideration through specially written sub-routing program. The results of the simulations are compared with the previously obtained experimental data for the lost foam iron casting.

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