Re-engineering of Cast Product by Topology Optimization

Topology optimization is useful to carrying out the weight reduction and in process cost reduction can be achieved. This kind of optimization input shape and size modification and optimization give us improved product in reduction of material. For this study, planet pinion carrier is selected for topology optimization. Software gives an innovative real-time picture of company activities and ecosystem and links people, ideas and data in a single collaborative environment. The 3DEXPERIENCE platform as an operating system helps companies to achieve operational excellence. Casting is a process where allowances and other things are provided and if we could able to optimize the material and weight of the casting there is a scope for optimization the material size and shape in casting process. Planet pinion carrier which is a cast product is taken from well-known industry for topology optimization. For optimization that product first 3D model is done and this 3D model is given as an input for topology optimization software. Force analysis is carried out by using ANSYS software and then topology optimization procedure is applied accordingly product is optimized. After topology optimization again force analysis is carried out. It has been found that 20 percent reduction is observed in this study. The part details and load conditions are given by well-known industry for topology optimization. Size, shape and cost is reduced by giving various load conditions in FUSION 360 software. Modeling and remodeling is done using software. Comparative study has been done using AUTOCAST software. Part details are calculated and also casting flow and real time for actual casting is simulated by using software.

Thermal Analysis of Al-5Ti1-1B Ligature

At present, casting and wrought high-strength and light aluminum alloys are widely used in the creation of a number of products and units in mechanical engineering, aviation and space technology. The process of developing alloys includes the formation of initial design data covering the operating conditions, the necessary physical, mechanical and other characteristics of products, and also considers the requirements of manufacturability in their manufacture and ensuring a given structure. To achieve these goals, when smelting aluminum alloys, Al-Mg, Al-Cu, Al-Mn, Al-B, Al-Ti ligatures are used. Despite the widespread use of ligatures, there is no single set of requirements for their quality. However, recent studies in the field of structural heredity in the "charge - melt - cast product" system have shown that the structure of the ligature has a significant hereditary effect on the crystallization process, structure and properties of the modified alloy. In this work, a study of the Al-5Ti-1B master alloy was carried out using synchronous thermal analysis, which made it possible to establish such properties as: the magnitude of the thermal effect, the temperature of its onset, enthalpy, and the crystallization interval. The results obtained make it possible to expand the bank of initial data to improve existing programs for modeling casting processes and to develop new ones.

The effect of rotational speed on quality of sound vertical centrifugal castings tin

Centrifugal casting plays a key role in manufacturing processes. In this process, the flow of the molten metal in particular, plays a significant role in defining the quality of final cast tube. The current study is an experimental work that focuses on the effect of fluid flow speeds on the quality of final cast product. The study was conducted using the vertical centrifugal casting with tin as the primary raw material. It is observed from the study that for the given manufacturing conditions, a speed 1050 rpm produced the sound castings. The micrographic studies of these cast products revealed an excellent grain structures. The improvement in the material hardness was also observed.

CRUSHING CHARACTER OF SAND-SODIUM-SILICATE MIXTURES STRUCTURED BY STEAM-MICROWAVE TREATMENT

At the present, from among the known methods of sand-sodium-silicate mixtures structuring, the least studied, but the most promising, is the method of steam-microwave solidification. Among unexplored elements of steam-microwave solidification method is nature of mixtures destruction. This is especially important for determining the ways to increase the sand-sodium-silicate casting molds and cores strength before pouring and lowering their strength by the time when casting should be knocked out the mold and the core from cast product. Knowledge about mixture destruction nature is also necessary for appropriate technical solutions elaboration concerning sand regeneration. In this regard, the purpose of the present work has to be nature of sand-sodium-silicate mixtures structured by steam-microwave solidification method destruction establishing. Quartz sand cladded with sodium-silicate solute has been used in the present investigation. Mixture (cladded sand) structuring has been carried out by microwave radiation at nominal magnetron power of 700 W and radiation frequency of 2.45 GHz in area of standing waves. To cladded sand structuring, 1 g water portion has been added, which has been placed in bottom of container in which mixture has been microwave treated. To make decision on mixture destruction nature, images of structured mixtures destruction places within one grain (sand grain), which are typical for adhesive and cohesive character of destruction, obtained with scanning electron microscope have been used. It has been found that with sodium-silicate solute for quartz sand cladding mass content from 0.5 to 6 % (by weight) increasing, as well as with mixture processing by the method of steam-microwave solidification duration increasing, mixture compression ultimate strength increases according to dependence closed to exponential. Character of structured mixture destruction, in this case, is not depend on sodium-silicate solute used for quartz sand cladding content, but depends on steam-microwave solidification duration. With its time increasing it changes from adhesive to mix or from adhesive to mixed and cohesive.

Simulation Based Mold Design Optimization of a Spring Flap Casting

The complex nature of metal casting process brings about a need to simulate it before undertaken in a foundry. Casting simulations provide insights on flow of molten metal within the mold, solidification sequence, nature and location of defects etc. Moreover, mold design can be optimized to minimize defects without undergoing physical trials-and-errors as previously practiced in traditional metal casting. This study is based on casting an ASTM A216 WCB steel spring flap for automotive suspension system using a simulation based optimized mold design. The initial and optimized mold designs are simulated in MAGMASoft for mold filling, solidification, stress distribution and defects prediction. The results of simulations and actual castings are found to be in good agreement. It is concluded that simulations are accurate in modeling casting process and in predicting defects followed by their minimization through mold design optimization. The use of auxiliary components in a carefully designed mold can lead to a nearly defect-free and high quality cast product.

Casting Octahedra for Reproducible Multi-Anvil Experiments by 3D-Printed Molds

Making consistent and precise octahedral pressure media is crucial for reproducible high-pressure experiments in the multi-anvil press. Here we report a new approach of casting octahedra using 3D-printed molds, and pressure calibrations for octahedra both with and without pre-existing gaskets (“fins”). The 3D-printed molds for casting octahedra from either Ceramacast 584-OF or 646 cement improve the reproducibility of the octahedra and allow for a pre-existing central hole (for the high-pressure cell assembly) in the final cast product. Pressure and temperature calibrations of the octahedra have been performed based on phase transitions in bismuth (Bi) and silica (SiO2), respectively, in order to determine the efficiency and reproducibility of pressure generation and thermal insulation for cast octahedra designed for use with 18/12, 14/8, and 10/5 multi-anvil assemblies. The pressure-generating efficiency of the 14/8 and 10/5 octahedra with pre-existing gaskets, cast from the 584-OF cement, is similar to that of the corresponding COMPRES (Consortium for Materials Properties Research in Earth Sciences) octahedra, and more efficient than pre-cast octahedra made from the same material but lacking pre-existing gaskets. The efficiency of pre-gasketed 18/12 octahedra made of the 646 cement is markedly lower than those of the 584 cement. However, the 18/12 large-volume octahedra, cast (with fins) from the ZrO2-based 646 cement, also provides efficient thermal insulation. Casting octahedral solid pressure media for multi-anvil experiments using 3D-printed “injection” molds is a low-cost and low failure-rate alternative for conducting reproducible experiments at high pressure in the multi-anvil apparatus.

Big Data Accumulation of L-Shape Extruded Alloys for Interior Parts for High-Speed Trains

L-Shape extruded alloys were manufactured by adopting aluminum alloy as the candidate lightweight alloy to be used for interior and exterior materials of high-speed trains. The cast product was extruded using the air slip (AS) casting method and the direct casting (DC) method. The product was again heat-treated with T5 or T6 tempering. According to literature research, the candidate alloys were selected as 6063, 6N01, 6061, 6060, 6005 and 5083 alloys. These alloys were extruded after casting and heat-treated and their properties such as the hardness, microstructure and tensile properties were evaluated. The hardness, microstructure and tensile properties of the selected 6063, 6N01, 6061, 6005 and 5083 aluminum alloys in the present study are similar to those of external materials made by Alcan, Canada. Mechanical properties of the extruded materials were comparable to those of external materials (manufactured by Canada, Alcan). The hardness, microstructure, and extrusion characteristics of AA6063, AA6N01, AA6061, AA6005, AA6060 and AA5083 alloys selected in the present study through literature review are similar to those of external materials (Canada, Alcan). By performing extrusion, under the conditions of high-speed railway, the process conditions for manufacturing extruded materials with complicated shape to meet the requirements of vibration resistance and airtightness have been established. Therefore, it was proved to be sufficient as the interior and exterior materials of high-speed train.