scholarly journals Feeding and Gating System Design and Simulation of Flange Roller of Hydrators for Yield Melioration

10.29007/fs9r ◽  
2018 ◽  
Author(s):  
Purvi Chauhan ◽  
Mohit Anuvadiya ◽  
Vivek Chauhan
Keyword(s):  
System Design ◽  
Metal Flow ◽  
Casting Process ◽  
Simulation Software ◽  
Casting Simulation ◽  
Gating System ◽  
Methods And Techniques ◽  
Mould Cavity ◽  
Effectiveness And Efficiency ◽  
Molten Metal Flow

The aim of this paper is showing the advantage of simulation technology in Casting. Casting simulation technique is widely used in foundries and casting industries. Casting simulation simulates the real casting phenomenon and gives a virtual casting process as molten metal flow in mould cavity with respect to time and direction. This paper explains the methods and techniques of feeding & gating system uses to increase the yield of casting in the company. On the basis of the own research it can be stated, that introducing the simulation software bring the great changes in the company, for example: product improvement by prevention of defects, increasing of effectiveness and efficiency in the processes, reduction in timing, proper utilization of material, grater quality, less cost to fulfill defects.

Improving Casting Integrity Through the Use of Simulation Software and Advanced Inspection Methods

2012 ◽  
Author(s):  
Ike Sowden ◽  
George Currier
Keyword(s):  
Metal Flow ◽  
Casting Process ◽  
Simulation Software ◽  
Destructive Testing ◽  
Material Density ◽  
Fraction Solid ◽  
Engineering Team ◽  
Trial And Error Method ◽  
Shrinkage Cavities ◽  
Inspection Techniques

Casting integrity is essential for providing components that meet design criteria for strength and fatigue performance. As the leading method of manufacturing metal components in the rail industry, maintaining quality and consistency is a continuing struggle for car owners and builders. Internal shrinkage and voids due to insufficient metal flow are issues commonly found in casting molds which are not designed or utilized properly. Using casting simulation software, potential issues can be discovered upfront and robust mold designs can be created that offer a tolerance for the variance or variations in casting conditions that are present in the real world. Strato, Inc. has extensively studied the effectiveness of these simulations in foundries through advanced inspection techniques. It is evident that casting simulations can not only locate, but also explain shrinkage cavities and voids through material density plots and inspection of directional solidification via critical fraction solid time plots. This approach is markedly more efficient than the traditional trial and error method, where mold makers rely on experience and destructive testing to develop acceptable mold designs. With recent advances in simulation software, the labor and time-intensive ways of the past have been supplanted by a more scientific approach to the problem. Understanding the fluid dynamics and thermodynamics of the casting process provides a means of creating a stable, repeatable final product. This higher quality final product can be delivered faster to the customer and at a far less expense by identifying problem areas prior to the tooling and sampling processes. Case-studies explored by the Strato engineering team suggest that using this software decreases the fallout rate.

Automatic Control of Molten Metal Flow for Improving Casting Performance

2011 ◽  
Vol 693 ◽  
pp. 179-184
Author(s):  
Thomas Jarlsmark ◽  
Jan Strömbeck ◽  
Mikael Terner ◽  
Jerry Wilkins
Keyword(s):  
Molten Metal ◽  
Metal Flow ◽  
Casting Process ◽  
Direct Chill ◽  
Level Control ◽  
Level Measurement ◽  
Cost Efficient ◽  
Molten Metal Flow ◽  
Automatic Level ◽  
Rolling Ingot

The ways to gain better quality and higher casting performance is an urgent topic among aluminium producers today. This issue is also often on the agenda at conferences like this and the subjects and technologies to achieve this varies. Controlling the molten metal flow by maintaining predefined levels or level patterns is one of many powerful tools to reach this goal. Precimeter Control specializes in applications for non-ferrous molten metal level measurement and molten metal flow control. By integration, or retrofitting, any new or existing casting line can easily be automatically controlled and gain improved casting performance in a cost efficient way. This paper will focus on the main benefits from automatic level control and how some plants have achieved improvements in their casting process of DC (Direct Chill) slab (or rolling ingot) casting after implementing such technology.

scholarly journals Numerical Simulation of Reoxidation Processes

2020 ◽  
Vol 328 ◽  
pp. 02007
Author(s):  
Marek Bruna ◽  
Marek Galčík
Keyword(s):  
Numerical Simulation ◽  
Liquid Metal ◽  
Aluminium Alloy ◽  
Oxide Layer ◽  
Negative Impact ◽  
Casting Process ◽  
Simulation Software ◽  
Gating System ◽  
Alloy Casting ◽  
Positive Effect

Reoxidation is one of the main problem accompanying the aluminium alloy casting process. The oxide layer created on the melt surface during reoxidation is entrained into the bulk of liquid metal and “bifilms” are created. Bifilms have negative impact on cast quality and internal homogenity of final casting. Paper aim is to clarify the reoxidation phenomenon by visualization with the aid of ProCAST numerical simulation software. Experiemtnal work deals with the design of several types of gating systems (non pressurized and naturally pressurized) with vortex elements in order to determine how these elements affect the reoxidation processes. Achieved results clearly confirmed the positive effect of the naturally pressurized gating system with vortex elements. The evaluation focuses mainly on melt velocity and amount of oxides created in gating system and in mold cavity.

scholarly journals Defects Analysis Using E Foundry and Flow Simulation for Crank Case Casting

10.29007/xl1j ◽  
2018 ◽  
Author(s):  
Yogin Vekariya ◽  
Trushant Desai ◽  
Rakesh Barot ◽  
Balkrushna Sharma
Keyword(s):  
Molten Metal ◽  
Computer Technology ◽  
Metal Flow ◽  
Flow Analysis ◽  
Flow Characteristics ◽  
Flow Simulation ◽  
Casting Process ◽  
Gating System ◽  
Dross Formation ◽  
Defects Analysis

Casting process deals with the metal in the molten state. When the molten metal is poured into the mold box, Smooth and turbulence less flow with appropriate velocity is need to be ensured. Type of flow while pouring the molten metal has significant influence on the end characteristics of casting. Inefficient metal flow can result in error beyond altering the desired characteristics of casting. Dross formation while pouring the metal has direct connection with the type of flow of molten metal. In short, one cannot neglect the flow of molten metal on other hand expecting sound casting formation. Gating characteristics directly deals with the type of flow expected while pouring. To provide desired flow is one of the functions of efficient gating system. But it is very difficult to consider the flow characteristics while actually designing the gating system. Computer technology has taken leap to aid foundry engineer in control of metal flow. Simulation soft-wares have been equipped with provision of flow analysis while designing the Gating system.

Assessment of Suitability of the Design of Gating System with the Use of Simulation Software

2017 ◽  
Vol 756 ◽  
pp. 136-141
Author(s):  
Ján Majerník ◽  
Monika Karková ◽  
Ján Kmec
Keyword(s):  
Time Course ◽  
Production Efficiency ◽  
Simulation Software ◽  
Thin Wall ◽  
Design Phase ◽  
Gating System ◽  
Qualitative Properties ◽  
Temperature Changes ◽  
Casting Cycle ◽  
Mould Cavity

The quality of thin wall castings produced by metal die-casting depends on the coherence and consistency of various aspects influencing the process of casting cycle. The qualitative properties of castings should already be considered in the design phase of construction of the gating system. The simulation software is an effective facility for the initial revealing of defects of the design phase. The assessment of casting cycle by the means of simulation predicts an incidence of defects of the casting core in the design phase and therefore reduces both the incidence of defects in the production and the costs while the production efficiency is increased. The article deals with the assessment of the design of the gating system for a particular casting type. The filling of mould cavity, casting solidification and time course of temperature changes occurring in the selected locations of gating system were defined as parameters indicating the assumptions of design accuracy. Simulation tests were carried out in the NovaFlow&Solid program. The tests resulted in a conclusion evaluating and describing the adequacy of structural design of the gating system.

A system for computer-aided gating design for multi-cavity die-casting dies

2015 ◽  
Vol 231 (11) ◽  
pp. 1983-1999 ◽  
Author(s):  
Vijay Kumar ◽  
Jatinder Madan
Keyword(s):  
System Design ◽  
Computer Aided Design ◽  
Die Casting ◽  
Casting Process ◽  
Manufacturing Cost ◽  
Gating System ◽  
Industrial Case Study ◽  
Efficient Manner ◽  
Die Casting Die ◽  
Computer Aided

The gating system design for a die-casting die is a non-trivial task that involves a number of steps and computations, in which many factors related to part design, material, and process need to be accounted. In case of a multi-cavity die-casting die, the non-triviality of the gating system design increases manifold. The main contribution of this article is to develop a computer-aided system for design of gating system for multi-cavity die-casting dies. The proposed system applies design knowledge and rules, accounting for various influencing factors to design gating system elements and generate their computer-aided design models in an efficient manner. To demonstrate the capabilities of the developed system, the results for an industrial case study part are presented. We expect that the proposed system would help reduce manufacturing cost and lead time, alongside bridging gaps between design and manufacturing of the die-casting process.

Application of Numerical Simulation on Cast-Iron Pneumatic Hammer Housing

2011 ◽  
Vol 474-476 ◽  
pp. 432-435
Author(s):  
Guo Fa Mi ◽  
Li Lin Chen ◽  
Bao Zhong Liu ◽  
Hai Yan Wang
Keyword(s):  
Numerical Simulation ◽  
Cast Iron ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Gating System ◽  
Pneumatic Hammer ◽  
Shrinkage Defects ◽  
Simulation Results ◽  
D Model

The Pro/E software was used to generate 3-D model of pneumatic hammer housing casting. The solidification process of the casting was simulated by the numerical simulation software, View Cast. The location and scale of the shrinkage defects were shown in the results. The risers were designed by the View Cast software based on the simulation results. The reasonable risers were obtained after the optimization on the numerical simulation. And the parameters of gating system were got according to the simulation results calculated by the gating system designing function of View Cast. Then the solidification results demonstrated that the risers and pouring system could be planned by View Cast effectually. The reasonable casting process was obtained and the process has been proofed by the productive practice.

Gating System Design Optimization for Investment Casting Process

2019 ◽  
Vol 28 (7) ◽  
pp. 3887-3893
Author(s):  
Marek Bruna ◽  
Dana Bolibruchová ◽  
Richard Pastirčák ◽  
Anna Remišová
Keyword(s):  
Design Optimization ◽  
System Design ◽  
Investment Casting ◽  
Casting Process ◽  
Gating System ◽  
Investment Casting Process ◽  
System Design Optimization

Forecast of Shrinkage Porosity of Aluminum Wheel Liquid Die Forging in Solidification Process and Process Optimization

2013 ◽  
Vol 690-693 ◽  
pp. 2236-2239
Author(s):  
Hai Bo Yang ◽  
Xing Sheng Zhao ◽  
Wei Zhong Fan ◽  
Xue Wen Chen ◽  
De Ying Xu
Keyword(s):  
Aluminum Alloy ◽  
Process Optimization ◽  
Solidification Process ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Orthogonal Test ◽  
Casting Simulation ◽  
Casting Technology ◽  
Casting Simulation Software

Using ProCast casting simulation software, the solidification process of the Aluminum Alloy steel casting was simulated according to its scene casting process, and the shrinkage porosity defect was forecasted. Based on the simulation, the casting technology was improved using the orthogonal test. An optimized plan was obtained, which provided a reference for the actual production of the casting.

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