Gravity process foundry simulation

In this work, they going to use a foundry simulation software to compare the virtual vs real results and try to reduce the time of the real process in the foundry area. In the real process they work with the re-engineering process of the pistons, first they take the original element and take the physical properties (length, width, thicknesses, etc.), after make a cast design and is assigned some parameters for the process, planning the process to make a test, after the casting process it goes to the machining process and finally the final inspection says if all the process during the tests is correct, if not, we need to take others parameters or casting design. With this project is going to be possible to save time in the foundry area and make a virtual process to see the result and change all the necessary things to have a perfect process.

Weldment to Casting Conversion Using Topology Optimization

The automobile and off highway industries grapple with dilemma of making a required component out of a weldment by welding different plates together or making a single component using a casting manufacturing process. The decision is always based on many parameters viz. volume of manufactured components, tooling cost involved, dimensional stability required, cost of welding, fatigue strength required etc. As the volume of the manufactured components increases, the cost of casting and its tool goes down and hence it makes sense to convert the weldment into a casting. A traditional method to do this is to convert the weldment into a casting based on functionalities and experience. In this paper, a topology optimization based approach is used to understand and decide the most optimal usage of the material based on the different constraints. In this paper, considerations of weldment to casting conversion, usage of topology optimization to arrive at final design and strength and fatigue life calculation are discussed. Keywords: Weldment, Topology Optimization, casting, Design for Manufacturability

Optimization of Shrinkage Porosity in Grinding Media Balls by Casting Design Modification and Simulation Technique

Shrinkage porosity or cavity are associated with the solidification of the metal either due to gas/air entrapment or when the shrinkage occurring during solidification is not entirely compensated by the riser. Shrinkage cavities occurring in the casting reduces its strength which leads to unfulfillment of the desired serviceability. In this paper, casting design has been modified using the DISA manual to achieve directional solidification which directly relates to improvement of casting quality. The running of metal from pouring basin into casting along with solidification has been analysed through PROCAST which is a casting simulation software based on Finite Element Method and CAFE (Cellular Automata Finite Element) Model. The feeding system of the casting has been modified in terms of shape and volume to minimize air aspiration effect and promote directional solidification. The model used is of grinding media balls casting of high chromium cast iron. The feeding pattern, feeding velocity and solidification with respect to pouring temperature, pouring rate, ambient temperature and film coefficient has been analysed. The final optimum range of all parameters with corresponding minimum shrinkage porosity in casting was obtained. Main aim was to minimize shrinkage porosity in the main casting, ignoring gating and feeding system. The actual minimization of shrinkage porosity comes out around 56 %.

Expert methods of developing of innovative technologies for the production of cast tools. Part 1. Formation of a complex of functional indicators of technology

A method for the development an effective technology for casting of billets of insert cutters with specified properties from high-speed steels for milling cutters of rotors of mining combines is proposed, including the identification of a set of goals, the choice of priority technology and the determination of the specified characteristics of the technology. An alternative method of expert assessment is proposed, which ensures high reliability of the results. Keywords: innovative technology, casting, design, expert assessment method. [email protected], [email protected]

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

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.

Novel Sprue Designs to Reduce Casting Defects in Nickel-Aluminum Bronze: A Computational Study

As 3D Sand-Printing technology becomes more widely available to the casting market, the search for opportunities to take advantage of its freedom of design is critical for its rapid adoption by the casting community. This original research investigates casting design principles towards defect-free alloy Nickel-Aluminum Bronze (NAB). This is an alloy of interest for marine applications due to its corrosion resistance, mechanical strength and good castability. Numerical modeling of flow within a casting is examined, and rigging redesigns are proposed to improve casting quality by controlling flow behavior. It has been demonstrated that turbulence and filling velocity are determining factors that seriously impact casting performance due to the generation of casting defects. Among these are bifilm formations, gas and sand entrapment and cold shut. This work examines the effectiveness of mathematically designed rigging components in controlling mold filling and compares the results to a conventional casting rig. Design solutions are proposed using 3DSP that can be directly applied to casting operations of Nickel-Aluminum Bronze. The results from this study demonstrate the effectiveness of mathematically designed sprues to reduce filling velocity of Nickel-Aluminum Bronze. The procedure followed here can be extended to marine casting production environments. Findings from this study can be seamlessly transferred to castings of any geometry, alloy and pouring conditions.