Numerical simulation and experimental investigation of a thin-wall magnesium alloy casting based on a rapid prototyping core making method

Fu, Yu; Wang, Han; Zhang, Chen; Hai, Hong

doi:10.1080/13640461.2017.1365477

Cited by 9 publications

(3 citation statements)

References 21 publications

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“… ProCast software with the simulation of sand casting process. The simulation results, showed the slot gate system exhibiting a better performance than the bottom gating system with respect to solidification and shrinkage porosity [42].…”

Section: Numerical Simulationmentioning

confidence: 95%

Effectiveness of Feeding System for Enhanced Product Quality in Sand Casting Industries

2019

IJRTE

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This review article deals with the importance of process parameters and the recent developments in modern tool technology in the success of smart productivity for casting process of all types. Various influencing factors such as design, location and the number of gating on feeding mechanism were discussed vis-a-vis casting defects. The review revealed reduction in the defects such as air bubbles, blow holes, shrinkage defects and mechanical properties of the casting parts through selection of an optimum feeding design. Variations in fillet radius and thickness on the feeding system were found to be the factors affecting the location of the hot spot. Accordingly, the mobility of the hot spot was controlled by geometrical modifications in the feeding system. In addition, the formation of pinholes and solidification defects could be reduced through a proper arrangement of the feeding system. The rapid growth in implementing simulation techniques in the casting process can assist the enhancement of yield with minimum production cost. This article provides a data base relating to the merits and demerits of various factors and material systems with their industrial applications for enabling further research in the casting process

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Section: Numerical Simulationmentioning

confidence: 95%

Effectiveness of Feeding System for Enhanced Product Quality in Sand Casting Industries

2019

IJRTE

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“…Furthermore, computational modelling was used to provide valuable insights into molten metal flow, heat transfer, solidification and mould filling in this current investigation, similar to previous studies [1,2]. Also, the simulation process aimed to mitigate the casting design phase by refining the casting conditions, minimising material waste and human resources.…”

Section: Introductionmentioning

confidence: 95%

Applicability of Angular Orientations of Gating Designs to Quality of Sand Casting Components Using Two-Cavity Mould Set-Up

Rajkumar

Rajini

Prabhu

et al. 2021

Trans Indian Inst Met

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This study aimed to examine integrity of two-cavity sand casting products in relation to angular orientation of gating design. Two angular orientations of 60° and 45° were investigated experimentally and numerically, and compared with the efficiency of a 90° gating system. The FLOW three-dimensional (3D) simulation was conducted to detect smooth filling and describe pattern of molten aluminium LM4 (Al-Si5Cu3) alloy flow. From the results obtained, turbulent flow was observed with vortex, which created larger surface gap to allow air entrapment in molten metal. For both instances, casting discontinuities such as blow holes, pin holes, sponge shrinkage, sand inclusions and dross were observed on the cut 2 mm machined surfaces of the moulded components with various degrees of intensity. Visual analysis, optical microscopy, ultrasonic and X-ray measurements were conducted to check accuracy of the experimental components. All the defect detection methods depicted fewest manufacturing defects with 45° angular orientation, which was attributed to uninterrupted flow of molten metal and low backflow strain. The component with 90° exhibited significant defects, due to turbulent flow, entrapment of air bubbles, lack of mould filling and uneven solidification. These factors consequently caused irregular cracks in the material. Therefore, Practically, 45 o angular orientation of gating design with two-cavity mould set-up is hereby recommended for optimum/best quality sand casting of aluminium LM4 (Al-Si5Cu3) alloy components, as required in many manufacturing companies.

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“…More also, numerical simulation and experimental results have been obtained to predict critical component gate system and sprue arrangement [12]. The simulation results predicted porosity defect and filling sequence in bottom and vertical gate systems [13].…”

Section: Introductionmentioning

confidence: 99%

Experimental and simulation analysis on multi-gate variants in sand casting process

Rajkumar

Rajini

Alavudeen

et al. 2021

Journal of Manufacturing Processes

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Numerical simulation and experimental investigation of a thin-wall magnesium alloy casting based on a rapid prototyping core making method

Cited by 9 publications

References 21 publications

Effectiveness of Feeding System for Enhanced Product Quality in Sand Casting Industries

Effectiveness of Feeding System for Enhanced Product Quality in Sand Casting Industries

Applicability of Angular Orientations of Gating Designs to Quality of Sand Casting Components Using Two-Cavity Mould Set-Up

Experimental and simulation analysis on multi-gate variants in sand casting process

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