Simulation Study on the Investment Casting Process of a Low-Cost Titanium Alloy Gearbox based on ProCAST

Liao, Qiang; Ge, Peng; Lu, Guangxuan; Yang, Song; Ye, Wenhui; Gao, Jianping; Luo, Xian

doi:10.1155/2022/4484762

Cited by 7 publications

(4 citation statements)

References 22 publications

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“…Model building. Rheological squeeze casting process are simulated by ProCAST software with its advanced numerical algorithms and models to simulate flow, solidification and other processes during the casting process [9] . The profile diagram of the target wheel is shown in Fig.…”

Section: Model Establishment and Parameter Selectionmentioning

confidence: 99%

Study on Rheological Squeeze Casting Process of Ultra-high Strength Al-11Zn-1.8Mg-0.9Cu-0.15Zr-0.15Sc Alloy

Zijing,

Zhifeng,

Yongtao

et al. 2024

J. Phys.: Conf. Ser.

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7xxx series Al alloys with excellent mechanical properties are widely applied in aerospace, automotive, and defense industries. However, the casting performance of the alloy is relatively poor, and defects such as shrinkage porosity and thermal cracking are easy to occur during the solidification process. In this study, Al-11Zn-1.8Mg-0.9Cu-0.15Zr-0.15Sc alloy with excellent casting and strength performance developed by our research group, was studied by combining numerical simulation with experimental research. The simulation results show that hot joints appear in the thick wall of the wheel parts as the melt temperature increases. The increase of mold temperature and the decrease of squeeze pressure lead to the increase of the existence time of hot joints, which will aggravate the shrinkage and micro-segregation of castings. The experimental results show that electromagnetic stirring melt treatment can significantly improve melt uniformity, refine grain, and a wheel-shaped part with high performance can be obtained when the melt temperature, the mold temperature, the squeeze pressure are chosen as 660 °C, 200 °C, 50MPa, respectively.

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Section: Model Establishment and Parameter Selectionmentioning

confidence: 99%

Study on Rheological Squeeze Casting Process of Ultra-high Strength Al-11Zn-1.8Mg-0.9Cu-0.15Zr-0.15Sc Alloy

Zijing,

Zhifeng,

Yongtao

et al. 2024

J. Phys.: Conf. Ser.

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“…ProCAST casting simulation software (version 2021.5) is used to simulate the casting process. Ease of filling and avoiding casting flaws should be taken into account while designing the casting system [31][32][33][34]. There are high dimensional accuracy requirements for the exhaust elbow's straight pipe and elbow at the thin-walled construction, so avoid setting up in these inner-runner sections.…”

Section: Pouring System Designmentioning

confidence: 99%

Study on the Optimization of Investment Casting Process of Exhaust Elbow for High-Power Engine

Xie,

Lv,

Dong

2024

Metals

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The high-power engine exhaust elbow has a complex construction, which makes it susceptible to casting flaws that could negatively impact its functionality. Therefore, the investment casting scheme was established and optimized in this study in order to cast structurally complete exhaust elbows for high-horsepower engines. ProCAST software was used to simulate and optimize the casting and solidification processes. The optimal process parameters were determined as follows: pouring temperature of 1650 °C, pouring speed of 1.5 kg/s, and shell preheating temperature of 1050 °C. The optimization of the primary parameters of the casting process, along with the results of dimensional accuracy analysis, shape and positional deviation, and defect detection, were validated through testing. The results indicated that the optimized castings had no casting defects and complied with the design specifications.

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“…Te size and morphology of grains, the distance between dendrites, segregation and precipitation of dissolved substances, porosity, and other defects signifcantly depend on the thermal behavior of the metal-mold system during crystallization [1]. In particular, casting defects and the solidifcation process were analyzed in the work [2]. Te results show that the defects can be predicted by the simulation result exactly.…”

Section: Introductionmentioning

confidence: 96%

Research Thermal Fields in the Crystallization Process of Steel Cast Parts

Liutyi

Petryk

Mogylatenko

et al. 2022

Advances in Materials Science and Engineering

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In foundry production, the duration of metal crystallization of the cast part, as well as the distribution of the thermal field, are described by systems of analytical equations. There are a number of methods for modeling these processes, but their theoretical basis was formed at the end of the twentieth century, and it needs to be updated and clarified. Therefore, the aim of our work is to develop a new analytical method for researching the distribution of thermal fields in cast parts during crystallization. For the first time, on the basis of own analytical and thermophysical developments, it developed the analytical method for researching the thermal field of the casting during crystallization and cooling, which is based on establishing the kinetics of cooling of the casting surface in the foundry mold, the advancement of the crystallization front from the surface to the center of the casting, and the distribution of temperatures in the solid and liquid parts of the casting. The method is expressed in a number of analytical formulas, each of which describes the specific thermal process that occurs in the casting. The developed analytical method was used to research the crystallization of the casting in a one-time sand mold, using the example of researching the thermal field of the cast part made of carbon steel with 0.25% C, hollow cylindrical shape, with the wall thickness of 100 mm. The developed analytical method for researching the thermal fields of cast parts is the analytical basis for the refinement of applied computer programs for modeling crystallization and cooling processes in foundry production.

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Simulation Study on the Investment Casting Process of a Low-Cost Titanium Alloy Gearbox based on ProCAST

Cited by 7 publications

References 22 publications

Study on Rheological Squeeze Casting Process of Ultra-high Strength Al-11Zn-1.8Mg-0.9Cu-0.15Zr-0.15Sc Alloy

Study on Rheological Squeeze Casting Process of Ultra-high Strength Al-11Zn-1.8Mg-0.9Cu-0.15Zr-0.15Sc Alloy

Study on the Optimization of Investment Casting Process of Exhaust Elbow for High-Power Engine

Research Thermal Fields in the Crystallization Process of Steel Cast Parts

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