Minimizing Shrinkage Porosity by Optimizing Some Parameters of Al Alloy (6061T6) Using DOE

Response surface methodology is an efficient and powerful tool which is widely applied for casting optimization. In this research aluminum alloy wheel hub casting is done by using BOXBEHNKEN design, three level of each parameter were taken. Solid modeling of casting and gating system is done by CAD. Simulation of Aluminium Alloy (6061 T6) casting were perform in PRO-cast (2009.1) the simulation result indicates that selected parameters significantly affect the quality of casting. ANOVA is employed to examine the relationship between the factors. Input parameter namely flow rate, pouring temperature and runner size were taken to reduce the volume of shrinkage porosity. Experimental Design consist 15 experimental trials and output data obtained from simulation will be optimized through minitab-18. Result indicates that selected independent variables are significantly influence the response. ANOVA gives the optimized value of selected factors which reduces the porosity volume up to 30cm³. Keywords: Sand casting, Shrinkage porosity, Simulation, DOE, Response surface method.

Design and Optimization of Direct Drive Motor Alloy Wheel for Manual Wheelchair

The wheelchair is the primary rehabilitation device used to enable the movement capability of disabled people. To provide an appropriate wheelchair, the doctor will suggest the necessary customization has to be made on the existing one. However, the customization of a manual wheelchair is easy and cost-effective compared with the powered wheelchair due to simple structure and spare parts availability in the market... Because of the above, a novel concept is proposed. The rear wheels of the manual wheelchair are replaced with a Direct drive motor alloy wheel. CATIA – V5 is utilized to design the proposed wheel and ANSYS software is used to check its performance at different load conditions. The stress-bearing capability of different materials for various Direct drive motor weights is observed through structural analysis. The natural mode frequencies are found using modal analysis and its nature of vibrations is verified. The harmonic response analysis is used to test the nature of deformation and stress concerning natural frequencies for the applied force.

Design and optimization of Direct drive motor Alloy wheel for manual wheelchair

The wheelchair is the primary rehabilitation device used to enable the movement capability of disabled people. To provide an appropriate wheelchair, the doctor will suggest the necessary customization has to be made on the existing one. However, the customization of a manual wheelchair is easy and cost-effective compared with the powered wheelchair due to simple structure and spare parts availability in the market... Because of the above, a novel concept is proposed. The rear wheels of the manual wheelchair are replaced with a Direct drive motor alloy wheel. CATIA – V5 is utilized to design the proposed wheel and ANSYS software is used to check its performance at different load conditions. The stress-bearing capability of different materials for various Direct drive motor weights is observed through structural analysis. The natural mode frequencies are found using modal analysis and its nature of vibrations is verified. The harmonic response analysis is used to test the nature of deformation and stress concerning natural frequencies for the applied force.

Design and simulation of Helmholtz resonator assembly used to attenuate tire acoustic cavity resonance noise

Tire acoustic cavity resonance noise (TACRN) is a typical annoying lower-frequency interior noise of a passenger car. The widely used attenuating method of attaching the porous sound absorption material in tire cavity can reduce TACRN effectively, but causes the increase of tire-wheel assembly weight and cost, also the poor durability. Additionally, the Helmholtz resonator (HR) is also used in the wheel of some cars although having only narrow effective band. The existing investigation shows that the frequency of TACRN varies with the car speed and load and also has the split characteristics. The change of TACRN frequency causes a certain difficulty to suppress TACRN effectively. Aiming at this problem, in this paper, TACRN frequency range of a specific tire cavity under different operating conditions is first calculated and analyzed. Then, for a specific aluminum alloy wheel, a HR assembly including several HRs is designed to make the natural frequencies of HR assembly cover the TACRN frequencies. Finally, the reduction effect of TACRN is simulated and evaluated by comparing the sound fields in tire cavity with/without HR assembly under same volume velocity sound source. This work is helpful for attenuating TACRN effectively under the changing operating conditions.

Design and Analysis of Alloy Wheel

Importance of wheel in the automobile is obvious. The vehicle (car) may be towed without the engine but at the same time even that is not possible with out the wheels, the wheels along the tyre has to carry the vehicle load provide cushioning effect and cope steering control. The main requirement of automobile wheel it must be strong and perform all operations above functions. It should be balanced both statically as well as dynamically. It should be lightest possible so that the unsprung weight is least. The wheel has to pass three types of test before going production, they are cornering fatigue test. Radial fatigue test and Impact test. In this thesis radial fatigue analysis is done to find the number of cycles at which the wheel is going to fail. The wheel is meshed using SOLID 45 element. A load of 2500N was applied on the hub area of the wheel and a pressure of 0.207N/mm2 is applied on the surface of rim.

Study on casting design and analysis of magnesium alloy wheel

PurposeThis research establishes a suitable casting model for magnesium alloy wheel. The casting of the wheel is an element that must be considered in the design of the wheel. Casting is an important basic process and technology in the field of machinery which is widely used in production, transportation, national defense, social life and other aspects. Computer numerical simulation of the casting process can shorten the product manufacturing cycle, reduce product costs, reduce casting defects and ensure product quality. The casting material in this study is AZ91 magnesium alloy used for wheel lightweight.Design/methodology/approachLightweight research of automobile is a significant trend, and people are paying attention to the lightweight design of automobiles. Higher requirement was proposed on design and casting performance of the wheel which is an important part of lightweighting vehicle. In order to achieve better quality, the parametric studies of alloy wheel and casting are necessary. This research designs a new model of automobile wheel, to ensure energy efficiency, the wheels must be as lightweight as possible, using magnesium alloy material for lightweight.FindingsAnalysis of casting process is a very complex issue. This research based on finite element theory and actual production, designed reasonable casting model, instant filling and solidification data were obtained. Aiming at reducing casting defects, process improvement of casting riser structure was designed. On the basis of the foundation, it has important guiding significance for actual foundry production.Originality/valueThis research establish a suitable casting model for magnesium alloy wheel. Aiming at reducing casting defects, process improvement of casting riser structure were designed.