Numerical simulation and design of casting system for stainless steel exhaust manifold

Abstract

Abstract. During operation, exhaust manifolds must bear the corrosion of high temperatures and repeated stress, which can easily lead to cavitation, corrosion, and creeping damage in the casting structure and affect product safety. To improve the structure of exhaust manifolds and increase their service life, we employed AnyCasting mold flow analysis to SUS304 stainless steel exhaust manifolds. We examined the influence of casting system design and process parameters such as ceramic shell temperature, casting temperature, and pouring speed on the filling and solidification processes of the liquid metal. Finally, we used the Niyama criterion to predict the probability and distribution of shrinkage porosity defects in the exhaust manifold and made improvements to enhance the quality of exhaust manifold castings.

Manufacturing of Wear Resistant Iron-Steel: A Theoretical and Experimental Research on Wear Behavior

“…Prior to casting, Anycasting software was used for casting analysis of the model for molding, filling of the mold and prevention of internal cavities. In the Anycasting, casting shape, casting type, runner, and other parts were first defined with the Anypre module and the mold area was created by selecting the casting area and runner axis [6,7]. Then, a theoretical analysis was carried out as shown in Figure 1 to get results such as casting filling time, solidification time, shrinkage cavities, which are of vital importance.…”

Archives of Foundry Engineering

“…The superheated metals alloys in the liquid state can be treated as the viscous incompressible fluids [7,9]. The mathematical description of the casting solidification process considering the liquid metal movements is based on the solution of the following equations system in a cylindrical axial-symmetric coordinate system [7][8][9][10][11] -the momentum equations…”

“…These studies focus mainly on obtaining castings without shrinkage defects with high mechanical properties through appropriate control of their feeding [1][2][3][4] or design of layer castings that are resistant to corrosion or have high heat resistance [5]. Conducting research on real objects is significantly difficult due to the lack of visibility and high temperatures taking place there, which is why only computer simulations make it possible to improve casting methods [6][7][8][9][10][11]. In this article, the process of casting solidification is analyzed, considering the phenomena of heat exchange and fluid flow, starting from the moment of filling the metal mould by molten metal and ending with the complete solidification of the casting.…”

Improvement of quality and yield for investment casting of centrifugal pump impeller by tilting mold and optimizing runner/riser system

“…The data obtained by MAGMASOFT software were used to analyze thermal behavior of molten metal. Huang et al [19] used AnyCasting software to model mold ow analysis for the investment casting of stainless steel exhaust manifolds and presented optimized gating system to enhance the quality of the castings. Sun et al [20] employed ProCAST software to eliminate porosity defects in the investment casting of the exhaust manifold.…”