Sensitivity analysis and nonlinear programming applied to investment casting design

Ebrahimi, Saeed; Tortorelli, Daniel A.; Dantzig, Jonathan A.

doi:10.1016/s0307-904x(96)00155-2

Cited by 19 publications

(6 citation statements)

References 10 publications

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“…For injection moulding, the purpose is to optimise the Thermal optimisation in sand casting 395 filling positions and the flow of the melt into the die. For casting optimisation, the research group at Illinois has addressed both solidification and flow in gravity sand and investment casting processes (Morthland et al, 1995;Ebrahimi et al, 1997;McDavid and Dantzig, 1998). In each case, the principles outlined in Tortorelli et al (1994) have been applied to establish an optimal design.…”

Section: Optimisation and Process Simulationmentioning

confidence: 99%

Thermal optimisation in the sand casting process

Lewis

Manzari²,

Gethin³

2001

Engineering Computations

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The general procedure of thermal optimisation in the sand casting process is addressed. Various aspects of design including the size and position of feeders and chills are discussed and practical approaches are presented to search for optimum design configurations. An algorithm is also presented for finding the optimum size, position and number of chills in a sand casting process. The presence of the chill(s) in the casting configuration is simulated using a one‐dimensional heat conduction model and proper inter‐facial heat transfer coefficients. The method is efficient as all computations are carried out on the same grid and there is no need for re‐meshing due to re‐sizing or re‐positioning of the chills. A finite element thermal analysis module is linked to a commercial optimisation tool to search for the optimum set of design variables and a computationally efficient sensitivity analysis method is introduced. Three sand casting test cases are solved to validate and demonstrate the optimisation procedure and these show its use to determine the optimum size, location and number of feeders and chills on a section through a casting.

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Section: Optimisation and Process Simulationmentioning

confidence: 99%

Thermal optimisation in the sand casting process

Lewis

Manzari²,

Gethin³

2001

Engineering Computations

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“…Efforts can then be focused on measuring the most important properties. 3 In order to run a simulation, the user must specify the geometry, material properties, and boundary conditions. The interfacial transport between the casting and the mold is incorporated as a boundary condition, usually as a heattransfer h coefficient defining the heat flux q between the casting and the mold…”

Section: Macro-scale Phenomena: Fluid Flow and Heat Transfermentioning

confidence: 99%

Solidification modeling: Status and outlook

Dantzig

2000

JOM

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Solidification modeling is a complex and highly advanced field. This article examines the state of the art in solidification modeling, including physical phenomena of solidification such as heat extraction, transport processes within a casting, and dimensional changes in the casting and mold during solidification. Also examined are current efforts to model these phenomena and the strengths and weaknesses of these efforts. Finally, obstacles to solidification modeling, such as speed and cost of the process, are considered, along with the likelihood those obstacles will be overcome.

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“…The solidi cation front is attened by a speci ed temperature distribution obtained by controlling the temperature on the furnace wall. Ebrahimi et al 17) optimized investment casting, such as the rigging systems and the mold wrap by nite element solidi cation heat transfer analysis and design sensitivity analysis. The solidi cation pattern can be controlled by the thickness of the mold wrap.…”

Section: Introductionmentioning

confidence: 99%

Flattening the Solidification Front by Varying the Wall Thickness of the Mould in Directional Solidification Technology

Lian

Zhang

2016

Mater. Trans.

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A non-planar solidi cation front can cause many defects in the directional solidi cation process. The irregular shape of the cross section of the cast leads to a non-uniform heat distribution and hence causes a non-planar solidi cation front. This paper provides a method to decrease the circumferential temperature gradient in the directional solidi cation process by varying the wall thickness of the mould. The relationship between the wall thickness and the control parameter has been determined. An optimization algorithm for obtaining the control parameter and the corresponding wall thickness of mould is presented with three simulation examples provided to verify the superiority of this method. According to the results the circumferential temperature gradients can be reduced by 68.7%, 72.0% and 88.2% respectively. Moreover, the transverse temperature gradients are reduced by 57.3%, 60.8% and 89.3% accordingly. The solidi cation front with a varying thickness mould is thus attened compared with the un-optimized one.

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Sensitivity analysis and nonlinear programming applied to investment casting design

Cited by 19 publications

References 10 publications

Thermal optimisation in the sand casting process

Thermal optimisation in the sand casting process

Solidification modeling: Status and outlook

Flattening the Solidification Front by Varying the Wall Thickness of the Mould in Directional Solidification Technology

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