scholarly journals The Effect of a Thin-Wall Casting Mould Cavity Filling Conditions on the Casting Surface Quality

2016 ◽  
Vol 16 (4) ◽  
pp. 222-226
Author(s):  
A. Trytek ◽  
A.W. Orłowicz ◽  
M. Tupaj ◽  
M. Mróz ◽  
O. Markowska ◽  
...  
Keyword(s):  
Casting Process ◽  
Casting Defects ◽  
Thin Wall ◽  
High Concentration ◽  
Casting Surface ◽  
Metallographic Examination ◽  
Furan Resin ◽  
Mould Cavity ◽  
Cavity Filling ◽  
Iron Manganese

Abstract The paper presents results of metallographic examination of faults occurring in the course of founding thin-walled cast-iron castings in furan resin sand molds. A non-conformance of the scab type was Observed on surface of the casting as well as sand buckles and cold shots. Studied the chemical composition by means of a scanning electron microscope in a region of casting defects: microanalysis point and microanalysis surface. Around the observed defects discloses high concentration of oxides of iron, manganese and silicon. A computer simulation of the casting process has been carried out with the objective to establish the cause of occurrence of cold shots on casting surface. The simulation was carried out with the use of NovaFlow & Solid program. We analyzed the flowing metal in the mold cavity. The main reason for the occurrence of casting defects on the surface of the casting was gating system, which caused turbulent flow of metal with a distinctive splash stream of liquid alloy.

Effect of Different Gating Systems and Sand Mold Binder on the Cast-Quality of Bicycle Frame Produced through Sand Casting Method

2020 ◽  
Vol 402 ◽  
pp. 100-107
Author(s):  
Akhyar ◽  
Husaini ◽  
Masri Ali ◽  
Nurdin Ali ◽  
Farhan Ahmad
Keyword(s):  
Water Glass ◽  
Casting Process ◽  
Sand Mold ◽  
Casting Defects ◽  
Casting Method ◽  
Mold Casting ◽  
Furan Resin ◽  
Bicycle Frame ◽  
The Impact

The bicycle frame produced through the metal casting process by recycling aluminum alloys can be an environmentally friendly alternative solution. Mold types and gating systems used generally affects the quality of the casting product. In this experiment, the effect of gating number and riser type variations (for sand binder) observed on casting defects, hardness, and impact value. Subsequently, chemical composition and microstructure of recycled aluminum metal from bicycle frames produced through sand mold casting are also evaluated. Three types of risers are bentonite, water glass, and furan resin. The results indicate that mold with two gating system has a low porosity as casting defects. The cast-bike frame produced using furan resin reaches the highest hardness value of 46 HRB compared to water glass and bentonite as the binder of sand-molds. The impact test observes 3.9 J carried out by the ASTM E23 sample at room temperature.

scholarly journals The Influence of Ingate Size on the Lost Foam Casting Process

2012 ◽  
Vol 12 (2) ◽  
pp. 171-174 ◽  
Author(s):  
T. Pacyniak ◽  
R. Kaczorowski
Keyword(s):  
Casting Process ◽  
Lost Foam Casting ◽  
Cavity Pressure ◽  
Calculation Algorithm ◽  
Original Calculation ◽  
Mould Cavity ◽  
Cavity Filling ◽  
Gas Gap ◽  
Lost Foam ◽  
Mould Casting

The Influence of Ingate Size on the Lost Foam Casting Process The article presents analysis of the influence of ingate size on the Lost Foam casting process. In particular, analysis of simulation tests has been carried out to determine the ingate size influence on the rate of filling of the mould cavity, pressure in the gas gap and size of the gas gap. A specially prepared mathematical model of the process and an original calculation algorithm were used in simulation tests of full-mould casting. The tests have indicated that the increase of the ingate size results in the increase of filling rate and increase of pressure of gases in the gas gap. However, significant influence on mould cavity filling occurs only when the ingate size is less than ~1 cm2.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Thin-Wall Steel Casting Process for Exhaust Components

2002 ◽  
Author(s):  
Nobuyoshi Sasaki ◽  
William L. Tordoff ◽  
Kazuyuki Kurisu ◽  
Yuji Yoshida
Keyword(s):  
Steel Casting ◽  
Casting Process ◽  
Thin Wall

Simulation of melt flow in coated mould cavity in the casting process

2003 ◽  
Vol 142 (2) ◽  
pp. 493-507 ◽  
Author(s):  
S.M.H. Mirbagheri ◽  
H. Esmaeileian ◽  
S. Serajzadeh ◽  
N. Varahram ◽  
P. Davami
Keyword(s):  
Casting Process ◽  
Melt Flow ◽  
Mould Cavity

Numerical Simulation of Casting Deformation and Stress of A356 Aluminum Alloy Thin-Walled Frame Casting

2021 ◽  
Vol 1033 ◽  
pp. 24-30
Author(s):  
Yi Dan Zeng ◽  
Li Tong He ◽  
Jin Zhang
Keyword(s):  
Aluminum Alloy ◽  
Casting Process ◽  
Mold Temperature ◽  
Hot Cracking ◽  
Thin Wall ◽  
A356 Aluminum Alloy ◽  
Pouring Temperature ◽  
Thin Walled ◽  
Alloy Castings ◽  
A356 Aluminum

One of the main reasons for the scrap of cast thin-wall frame aluminum alloy castings is deformation and cracking. It is an effective method for solving the problem by predicting the distribution of casting stress, clarifying the size of the deformation and the location of the crack, and taking necessary measures in the process. This paper uses the ProCAST software to simulate the thermal stress coupling of A356 thin-walled frame castings, analyzes the influence of pouring temperature, pouring speed and mold temperature on the stress field distribution of castings, predicts the hot cracking trend and deformation, and optimizes Casting process..

Ground Water Use Near an Open Dumpsite in a Peri-urban Community

2021 ◽  
Vol 47 (2) ◽  
pp. 252-257
Author(s):  
O.A. Mokuolu ◽  
I. Olaniyi ◽  
J.O. Iji
Keyword(s):  
Calcium Nitrate ◽  
Quality Parameters ◽  
World Health ◽  
Total Hardness ◽  
High Concentration ◽  
Residential Community ◽  
Physico Chemical ◽  
High Turbidity ◽  
Health Organization ◽  
Iron Manganese

Quality of groundwater used for drinking and domestic purposes near an open dumpsite was investigated. Groundwater parameters for wells GW1, GW2, GW3 and GW4 were analysed and their values were compared with World Health Organization (WHO) and Nigerian Standard for Drinking Water Quality (NSDWQ). Physico-chemical and bacteriological analysis were carried out to determine the quality. Parameters analysed include; Temperature, Turbidity, Total Hardness, pH, Alkalinity, Electrical Conductivity, Total Dissolved Solids, Total Suspended Solids, Total Solids, Magnesium, E-coli, Calcium, Nitrate, BOD, COD, DO, Chloride, Sulphate, Iron, Manganese and Lead. The results indicated that all parameters except turbidity, iron and lead were within the standards, all samples showed high concentration of iron and lead while GW1, GW2 and GW3 showed high Turbidity. The study concluded that groundwater situated around the dumpsite is unfit for drinking purposes. An engineered landfill located away from residential community was recommended.

scholarly journals Investigation of Shrinkage Defect in Castings by Quantitative Ishikawa Diagram

2017 ◽  
Vol 17 (1) ◽  
pp. 174-178 ◽  
Author(s):  
B. Chokkalingam ◽  
V. Raja ◽  
J. Anburaj ◽  
R. Immanual ◽  
M. Dhineshkumar
Keyword(s):  
Casting Process ◽  
Casting Defects ◽  
Remedial Measures ◽  
Pareto Chart ◽  
Root Cause ◽  
Ishikawa Diagram ◽  
Shrinkage Defect ◽  
Automobile Body ◽  
The Many ◽  
And Control

Abstract Metal casting process involves processes such as pattern making, moulding and melting etc. Casting defects occur due to combination of various processes even though efforts are taken to control them. The first step in the defect analysis is to identify the major casting defect among the many casting defects. Then the analysis is to be made to find the root cause of the particular defect. Moreover, it is especially difficult to identify the root causes of the defect. Therefore, a systematic method is required to identify the root cause of the defect among possible causes, consequently specific remedial measures have to be implemented to control them. This paper presents a systematic procedure to identify the root cause of shrinkage defect in an automobile body casting (SG 500/7) and control it by the application of Pareto chart and Ishikawa diagram. with quantitative Weightage. It was found that the root causes were larger volume section in the cope, insufficient feeding of riser and insufficient poured metal in the riser. The necessary remedial measures were taken and castings were reproduced. The shrinkage defect in the castings was completely eliminated.

Casting Process Design and Simulation of Large Cast Steel Bracket

2019 ◽  
Vol 815 ◽  
pp. 125-130
Author(s):  
Jia Ji Xiong ◽  
Fan Lin Meng ◽  
Qing Jin Liang ◽  
Chong Cao
Keyword(s):  
Process Design ◽  
Manufacturing Process ◽  
Cast Steel ◽  
Casting Process ◽  
Casting Defects ◽  
Optimization Scheme ◽  
Sand Core ◽  
Steel Cast ◽  
Simulation Results ◽  
Filling And Solidification

The casting process design of large cast steel supports is carried out, and the special integrated sand core and forged steel cast lugs are used to simplify the cavity manufacturing process. The ProCAST software was used to simulate the casting process of the stent, simulating the filling and solidification of the casting, and predicting the occurrence of defects such as shrinkage and shrinkage of the casting. According to the simulation results, the cause of the defects is analyzed, and the casting process of the stent is optimized. The simulation results show that the optimization scheme effectively reduces the casting defects and the surface of the stent is free from defects.

Sign in / Sign up

Export Citation Format

Share Document