Casting simulation and defect identification of geometry varied plates with experimental validation

Barot, R.P.; Ayar, V. S.

doi:10.1016/j.matpr.2020.02.575

Cited by 9 publications

(3 citation statements)

References 10 publications

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“…The Click 2 cast software is made by the Altair Software Company, used for the simulation of casting process, filling speed, shrinkage position and casting defects, etc. [10,11]. In this simulation model, the positions of the pouring cup and the metal pouring temperature were taken from the initial experimental parameters.…”

Section: Simulation Processmentioning

confidence: 99%

Simulation and experimental study on the Fenotec casting method of the engine block RV95

Trung

2023

Eureka: PE

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The new designs or new materials used in foundries for sand casting products in Vietnam now often rely on experience and adopt the try-to-fix method to gradually find the best implementation. This method is very time-consuming, and the product is often unsatisfactory in the first many castings. This study developed a casting simulation model to compare experimental and simulated results using the Fenotec molding technology for the RV95 engine body. The 3D simulation model that was used to simulate the casting process with the same boundary conditions as the experiment also gave similar results. The results show that when making new castings for the first time from experience, there are many casting defects such as cracking, metal deficiency, porosity, etc. In order to improve the casting results, the pouring gate, the arrangement of additional risers and the size of the runner were studied on the simulation to improve the defect results on the casting. After that, the parameters in the simulation model used in the experiment reveal that the molded product meets the required quality and no longer has defects. This molded product, after checking the mechanical and geometric parameters, can be put into mass production

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Section: Simulation Processmentioning

confidence: 99%

Simulation and experimental study on the Fenotec casting method of the engine block RV95

Trung

2023

Eureka: PE

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“…Sridhar et al, through this numerical investigation, estimated the temperature distribution profles by fnite element program (ANSYS) for diferent composition of composites [7]. Barot and Ayar obtained the cooling curves of plates with diferent geometric shapes by simulating the process of gravity casting with permanent mold and placing virtual thermocouples at diferent positions [8]. Chandra Kandpal et al efectively reduced the sand casting defects by adopting correct methods in the sand casting process to reduce the occurrence of casting defects [9].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation on Impeller Casting Defects and Optimization

Liu

Jia

Zhou

et al. 2023

Mathematical Problems in Engineering

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The numerical simulation is similar to the experimental research, which uses the computer. 3D printing is an experimental study, which is compared with simulation. 3D printing and precision casting of impellers are frequently used in industrial scenarios. To address the problem of low casting yield of aluminium alloy impellers in gypsum-type casting, three-dimensional modelling by magics, casting simulation, and parameter optimization method by applying ProCAST software are used to improve the casting yield of impellers. The results show that the optimized structure of the casting system is more reasonable, so that the shrinkage and shrinkage defects are concentrated in the location of the riser; the maximum stress value of the casting and the casing during the solidification stage is 2.71 MPa, which is much smaller than the stress limit of the casing; the maximum horizontal displacement of the casting along the X and Y axes after solidification is completed at 0.025 mm and 0.022 mm, respectively, and the maximum displacement along the Z axis due to the presence of the riser is 0.009 mm, which greatly improves casting accuracy and molding quality.

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“…Due to the wide and various Aluminum alloys applications it became a market demand because of its exceptional properties with a lower cost and least defects [1] in addition to the not economically feasible application of the numerical methods for the optimization of casting solidification process parameters [2], packaged software has become commercially available to support casting design, obtaining highly accurate simulation results [3]. The solidification process is a heat conduction problem involving a phase change, or the moving boundary problem because of the unexplored moving liquid-solid interface [4].…”

Section: Introductionmentioning

confidence: 99%

The Computational Fluid Dynamics Investigation on the Solidification of Aluminum Cast in Moulds with Different Thickness and the Influence of the Moderate Press

Ghoben¹,

Al‐Farhany

Kareem

2021

MSF

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The influence of applying an external distributed pressure along the upper surface of the molten metal (Aluminum ) during the solidification process on the temperature reduction profile was studied including the time of solidification of the cast and the phase change moving boundary location for two mould wall thicknesses (10mm and 15mm). A 3D model was built up by Solidworks and simulated by ANSYS FLUENT; each mould wall thickness was discussed for two press cases (1bar and 3bar) sequentially, comparing with no press cases. The discussion includes the ambient temperature effect, which is taken (300K then 310K), the overall cases that studied was 7 cases. The study shows a remarkable effect of press on the temperature reduction profile especially when mix with the mould thickness effect as well as the ambient temperature which has a great order in guiding the results. The results showed that the heat reduction increases by increasing the mould thickness as well as the applied pressure. Moreover, this effect will reduce the solidification time and the moving of the boundary of phase change become faster in appearance.

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Casting simulation and defect identification of geometry varied plates with experimental validation

Cited by 9 publications

References 10 publications

Simulation and experimental study on the Fenotec casting method of the engine block RV95

Simulation and experimental study on the Fenotec casting method of the engine block RV95

Numerical Simulation on Impeller Casting Defects and Optimization

The Computational Fluid Dynamics Investigation on the Solidification of Aluminum Cast in Moulds with Different Thickness and the Influence of the Moderate Press

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