Geometric Corrections for Propellers Patterns and Casting Molds

2015 ◽  
Author(s):  
Adam R. Kaplan
Keyword(s):  
Manufacturing Process ◽  
Casting Process ◽  
Sand Casting ◽  
Design Tool ◽  
Solidification Shrinkage ◽  
Manufacturing Methods ◽  
Correction Strategies

Once a propeller is designed, the geometry must be produced One of the most common manufacturing methods for modern propellers is to produce a thickened casting so that the final geometry can be machined through grinding or milling. To ensure the casting will encompass the final geometry, several geometric corrections must be applied to account for the sand casting manufacturing process. The corrections provide compensation due to solidification shrinkage, solid shrinkage, machining tolerance, and distortion during cooling. The objective of this paper is to review and understand the mechanisms that result in geometric differences during the casting process. Common correction strategies will be recommended for correcting design geometry for pattern creation. Lastly, an implementation of a generalized correction methodology will be demonstrated using HydroComp PropCad, a commercial design tool for propeller geometries.

Aluminum Foam, “Alporas”: The Production Process, Properties and Applications

1998 ◽  
Vol 521 ◽  
Author(s):  
T. Miyoshi ◽  
M. Itoh ◽  
S. Akiyama ◽  
A. Kitahara
Keyword(s):  
Physical Properties ◽  
Production Process ◽  
Molten Metal ◽  
Manufacturing Process ◽  
Aluminum Foam ◽  
Casting Process ◽  
Cellular Structures ◽  
Solidification Shrinkage

ABSTRACTThe production of foamed aluminum has long been considered difficult to realize because of such problems as the low foamability of molten metal, the varying size of cellular structures, solidification shrinkage and so on. Recently these problems have been solved by a number of researches and some manufacturers produce foamed aluminum by their own methods. We have been employing a batch casting process and manufacturing foamed aluminum under the tradename ALPORAS® since 1986. This paper presents the manufacturing process, physical properties and some typical applications of ALPORAS.

Defect Investigation of Sand Casted Aluminum Cooling Fan

2020 ◽  
Vol 991 ◽  
pp. 30-36
Author(s):  
Dedhy Prihtiantoro ◽  
Agus Dwi Anggono ◽  
Waluyo Adi Siswanto
Keyword(s):  
Manufacturing Process ◽  
Casting Process ◽  
Sand Casting ◽  
Product Performance ◽  
Defect Analysis ◽  
Complicated Shape ◽  
Cooling Fan ◽  
Domestic Use ◽  
The Common ◽  
Defect Investigation

Sand casting is one of manufacturing process that still exist today. Numerous products are produced to serve industrial and domestic use. Defect could lead to product performance, and unfortunately inevitable in a casting process. This paper aim to investigate typical defect resulted from sand casting process. An aluminum cooling fan was selected as the model since it has complicated shape with different thicknesses. The casted fan was investigated under photo micro for defect analysis. Porosity, gas inclusion, pinhole, and shrinkage were found as the common defects occured at different part of the fan.

Fabrication of Bicycle Frame of A356 Aluminum Alloys by Using Sand Casting

2015 ◽  
Vol 758 ◽  
pp. 131-135 ◽  
Author(s):  
Suyitno ◽  
Urip Agus Salim
Keyword(s):  
Manufacturing Process ◽  
Raw Materials ◽  
Welding Process ◽  
Casting Process ◽  
Sand Casting ◽  
Pipe Production ◽  
Pipe Welding ◽  
Bicycle Frame ◽  
A356 Aluminum ◽  
Welding Processes

Bicycle frames on the market are generally made from a pipe connected by welding process. Bicycles are made by big companies, because it requires forming technology of raw materials for the pipe production and complex welding technologies. In order to reduce the dependence on raw materials and pipe welding processes, an alternative technology for bicycle frame manufacturing process is investigated. This study is aimed to examine the use of casting technology in the manufacturing process of bicycle frame. Production of bicycle frames in limited quantities is possible by using the casting process. To achieve these objectives, it is necessary to redesign the bicycle frame suitable for the casting process. Prototypes have been produced and the first bike is in the testing phase. Initilly , the bicycle is relatively heavy (7 kg). The optimization of the design reduces to a light and strong frame. The frame has a weight of 3.74 kg. The prototype of the frame has been succesfully casted by sand casting method.

scholarly journals Classification of Metals used in the Sand Casting Process

2021 ◽  
Vol 11 (2) ◽  
pp. 13-19
Author(s):  
A. Arun ◽  
R. BalaKrishnan ◽  
R. Jayanthi ◽  
H M S. Kevin ◽  
A. Ranjith Raj ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Review Paper ◽  
Casting Process ◽  
Sand Casting ◽  
Complex Material

The Sand Casting Process And The Different Methods Used To Cast The Metals Are The Subjects Of This Paper. Casting Is A Manufacturing Process For Creating Complex Material Shapes. A Large Classification Is Needed To Understand The Metals Used By Researches, Why They Were Used, And What The Most Commonly Used Metal For Their Research Is. We Studied And Understanded The Various Types Of Sand Casting Processes Used By The Researchers In This Review Paper. And We Categorized And Graded All The Papers We Reviewed And Classified Based On Their Respective Study Areas And Material Use.

OPTIMISATION OF SAND CASTING PROCESS FOR IMPELLER USING TAGUCHI METHODOLOGY

2020 ◽  
Vol XVII (2) ◽  
pp. 23-33
Author(s):  
Faisal Hafeez ◽  
Salman Hussain ◽  
Wasim Ahmad ◽  
Mirza Jahanzaib
Keyword(s):  
Surface Roughness ◽  
Surface Defects ◽  
A356 Alloy ◽  
Casting Process ◽  
Sand Casting ◽  
Gate Length ◽  
Taguchi Methodology ◽  
Confirmatory Tests ◽  
Binder Ratio ◽  
Response Measures

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

scholarly journals Experimental and simulation analysis on multi-gate variants in sand casting process

2021 ◽  
Vol 62 ◽  
pp. 119-131
Author(s):  
I. Rajkumar ◽  
N. Rajini ◽  
A. Alavudeen ◽  
T. Ram Prabhu ◽  
S.O. Ismail ◽  
...  
Keyword(s):  
Simulation Analysis ◽  
Casting Process ◽  
Sand Casting

Production of Metal Matrix Composite Using a Bottom Tapping Stir Casting Furnace

2015 ◽  
Vol 772 ◽  
pp. 263-267 ◽  
Author(s):  
Ramanathan Arunachalam ◽  
Majid Al-Maharbi ◽  
Yahya Al Kiyumi ◽  
Elyas Aal-Thani ◽  
Mohammed Al Mafraji
Keyword(s):  
Continuous Improvement ◽  
Manufacturing Process ◽  
Metal Matrix ◽  
Low Cost ◽  
Casting Process ◽  
Stir Casting ◽  
Matrix Composites ◽  
High Quality ◽  
Reinforcement Material ◽  
Low Cost Manufacturing

Metal matrix composites (MMC's) have attracted the attention of researchers for quite some time. In the last 15 years, many studies have been reported in this field of MMC production through various routes. The most commonly used process for producing MMC is stir casting process whereby the reinforcement material is incorporated into the molten metal by stirring. It is a relatively low cost manufacturing process that is capable of producing high quality MMC. However, the process is associated with issues such as attaining uniform distribution of particles, wettability between particles and porosity in the MMCs. Because of these challenges, there has been continuous improvement in the process as well as the design of the furnace. In this research, an innovatively designed bottom tapping furnace has been used to produce the MMCs and the produced sample is characterized.

Thermal optimisation in the sand casting process

2001 ◽  
Vol 18 (3/4) ◽  
pp. 392-417 ◽  
Author(s):  
R.W. Lewis ◽  
M.T. Manzari ◽  
D.T. Gethin
Keyword(s):  
Casting Process ◽  
Sand Casting
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