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The choice of the gating feeding system of castings is made by trial and inevitable errors, which are the less, the more experience of the casting engineer who develops the type of system for different types of casting. The design of the gating system and the modeling of the casting process, the formation of casting, and the analysis of emerging defects can be made more efficiently due to the great possibilities of the computer simulation program “Polygon”. Considering the investment casting, the automated design program greatly simplifies the process of finding the best solution, as the investment casting is a complicated and a multiphase process, which requires taking many steps such as designing a press mold, building a cluster, et cetera. The factory design of the casting model is a stock of unified exemplary segments, which are interconnected and characterized by an unproductive usage of a top part. It is proposed to improve the model casting unit “Flange” of the current production, without changing the design of the model units, and increasing the number of models of the casting from one to four, which can lead to an increase in the yield of fit. In preparation for the calculation, the three-dimensional model was divided into a finite element mesh. The computer program calculates the process of solidification and formation of shrinkage defects for metal. The conducted computer experiment showed that this technology of casting arrangement, developed with the aid of the automated design program, can be used in production, which will significantly accelerate the implementation of the annual program, ensuring the production of high-quality castings, which is confirmed by the experimental fills. Programming processing in SprutCAM allowed to reduce processing time by minimizing idling and to obtain a trouble-free control program for the CNC machine.
The choice of the gating feeding system of castings is made by trial and inevitable errors, which are the less, the more experience of the casting engineer who develops the type of system for different types of casting. The design of the gating system and the modeling of the casting process, the formation of casting, and the analysis of emerging defects can be made more efficiently due to the great possibilities of the computer simulation program “Polygon”. Considering the investment casting, the automated design program greatly simplifies the process of finding the best solution, as the investment casting is a complicated and a multiphase process, which requires taking many steps such as designing a press mold, building a cluster, et cetera. The factory design of the casting model is a stock of unified exemplary segments, which are interconnected and characterized by an unproductive usage of a top part. It is proposed to improve the model casting unit “Flange” of the current production, without changing the design of the model units, and increasing the number of models of the casting from one to four, which can lead to an increase in the yield of fit. In preparation for the calculation, the three-dimensional model was divided into a finite element mesh. The computer program calculates the process of solidification and formation of shrinkage defects for metal. The conducted computer experiment showed that this technology of casting arrangement, developed with the aid of the automated design program, can be used in production, which will significantly accelerate the implementation of the annual program, ensuring the production of high-quality castings, which is confirmed by the experimental fills. Programming processing in SprutCAM allowed to reduce processing time by minimizing idling and to obtain a trouble-free control program for the CNC machine.
Flow of molten metal to the mold of continuous casting machine (CCM) is an insufficiently studied process up to the present day. This paper is a continuation of author’s works published in scien tific se rials last years. It shows the possibility of a theoretical research of motion kinetics and thermal flows of molten metal in the mold during traditional casting by using hydrodynamic theory and mathematical physics equations and a proven numerical approach. This familiar calculation methodology makes it possible to calculate flows of molten metal motions and their temperatures in the mold and to compare the obtained results with ones obtained during usage of other methods of metal pouring including proposed method. This paper describes and solves three-dimensional problem of determination of velocity and temperature fields in metal poured to CCM mold from the submerged nozzle to the round deflector. In addition, the calculation methodo logy described in previous works of the authors is used, namely, the constitutive equation system, numeric method, numerical scheme and algorithm for solving the problem. Hardened metal crust forming on the mold faces was not considered in this calculation. For the results objective analysis of the problem solving in two ways (traditional and proposed), the same theoretical (speed of pulling-out from crystallizer) and geometrical parameters of rectangular cross-section mold were taken. Application for an invention for the described alternative method of liquid metal supplying to rectangular mold was registered (No. 2018108974/02 (013808)). The article contains some results of numerical solution of the problem in particular schemes of molten metal flows and their temperatures over different sections of the mold.
A significant influence on stability of the process of filling the CCM mold with liquid metal is exerted by the structural and technological schemes and designs of used devices, modes and parameters of filling the mold with the melt. All this is due to the features of the devices used and the improvement of their design. The high requirements for such devices have determined the need to create new devices designs to reduce the time spent on preparation for work and maintenance and to improve the quality of resulting metal billets. In scientific literature, including patents, more and more articles and materials are devoted to the development of new and improvement of the existing methods of supplying and stirring liquid metal in CCM and devices for their implementation. Experimental studies of liquid metal flow in CCM are a long, complex and laborious process. Therefore, mathematical modeling by numerical methods is increasingly used for this purpose. The authors have proposed a new technology for pouring liquid metal into a mold and a device for its implementation due to the use of effect of a deep-bottom submersible nozzle rotating in the mold with eccentric outlet holes. The purpose of this work is to simulate by proven numerical method a new process of filling a rectangular CCM mold with liquid steel and stirring it. Based on the developed numerical schemes and algorithms, a calculation program was compiled. The article describes an example of calculating the steel casting into a mold of rectangular cross-section and flow diagrams of liquid metal in it.
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