Mold Filling and Solidification Studies of a Gray Iron Engine Block

1998 ◽  
Author(s):  
O. Gurdogan ◽  
V. Rubek ◽  
O. Selcuk ◽  
J. Haskett ◽  
H. U. Akay ◽  
...  
Keyword(s):  
Mold Filling ◽  
Gray Iron ◽  
Engine Block ◽  
Filling And Solidification

Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting

2011 ◽  
Vol 121-126 ◽  
pp. 254-258
Author(s):  
Bai Yang Lou ◽  
Fang Li Liu ◽  
Kang Chun Luo
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Casting Defects ◽  
Casting Simulation ◽  
Pressure Die Casting ◽  
Filling And Solidification

The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

Numerical Simulation of Mold Filling and Solidification Process for Beam Blank Continuous Casting

2012 ◽  
Vol 538-541 ◽  
pp. 506-509
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang
Keyword(s):  
Velocity Field ◽  
Continuous Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Filling Process ◽  
Continuous Casting Mold ◽  
Commercial Code ◽  
Solidification Speed ◽  
Filling And Solidification

Mold filling and solidification of molten steel for 750mm×450mm×300mm continuous casting mold of single SEN and double SEN are simulated by using CFD commercial code Flow-3d. The distributing diagrams of velocity field and temperature field and the location and shape diagrams of free-surface during mold filling process are obtained. Influences of single SEN model and double SEN model on velocity field and solidification are analyzed. It is found that double SEN model can lighten circumfluence intensity at the upper of mold, quicken solidification speed of steel liquid in the mold, which is favorable to improving the quality of billet and enhancing pull speed.

Numerical Simulation of Chilled Cast Iron Camshaft in Sand Casting Process

2010 ◽  
Vol 44-47 ◽  
pp. 117-121
Author(s):  
Bin Feng He ◽  
Zhu Qing Zhao
Keyword(s):  
Numerical Simulation ◽  
Cast Iron ◽  
Solidification Process ◽  
Casting Process ◽  
Mold Filling ◽  
Sand Casting ◽  
Simulation Results ◽  
Improved Technology ◽  
Filling And Solidification ◽  
Chilled Cast Iron

There are many kinds of casting defects such as insufficient pouring, cooling separation, crack, and shrinkage and soon on were formed in the mold filling and the solidification process, which affect the final casting performance. Based on the mathematical models of mold filling and solidification process, the numerical simulation of chilled cast iron camshaft in sand casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkages were predicted. According to the simulation results, an improved technology is proposed, and the shrinkages were eliminated efficiently. The simulation results are in good agreement with practical.

Numerical Simulation of Mold Filling and Solidification Behavior in Permanente Casting Process

2013 ◽  
Vol 313-314 ◽  
pp. 179-183
Author(s):  
Qing Ming Chang ◽  
Yin Kai Yang ◽  
Jing Yuan ◽  
Xia Chen
Keyword(s):  
Casting Process ◽  
Mold Filling ◽  
Permanent Mold ◽  
Gating System ◽  
Solidification Behavior ◽  
Mold Casting ◽  
Simulation Results ◽  
Permanent Mold Castings ◽  
Filling And Solidification

Melt flow and casting solidification are essential parts of the permanent mold casting process and affect significantly the quality of castings．For this reason, accurate prediction of mold filling pattern and temperature field in permanent mold castings plays on an important role in producing sound castings. In this paper, the model filling and solidification of a box casting produced from an aluminum alloy is studied. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate gating system, pouring rate, cooling line, a smooth mold filling, reduced shrinkages and other defects are available and desired sound castings can be produced.

Numerical Simulation of Die Casting for Semi-Solid Aluminium Alloy and its Mould Research

2011 ◽  
Vol 201-203 ◽  
pp. 2717-2720
Author(s):  
Yong Huang ◽  
Yao Huang ◽  
Qiong Wu ◽  
Xiao Ming Du ◽  
Cheng Zhi Wang
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Heating System ◽  
Mold Filling ◽  
Standard Samples ◽  
Solid Aluminum ◽  
Mould Cavity ◽  
Semi Solid ◽  
Filling Characteristics ◽  
Filling And Solidification

With consideration of the viscosity of semi-solid aluminum alloy slurry and the mold filling characteristics in die casting, the die-casting mould for semi-solid aluminum alloy has been designed and manufactured on the basis of the standard samples. The process of mold filling and solidification of semi-solid aluminum alloy in die casting was simulated by using ProCAST software. With combination of simulation results with die casting experimental data, the results indicate that the influence of heating system of the mould and cross section of ingate for the mould on flowing of semi-solid aluminum alloy in mould cavity is important in this work.

scholarly journals A Study Of Cylinder Bore Distortion In V6 Aluminum Alloy Engine Blocks

2021 ◽  
Author(s):  
Anthony Lombardi
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Gray Iron ◽  
Engine Block ◽  
Heat Treated ◽  
Potential Factors ◽  
Engine Blocks ◽  
Increased Strength ◽  
Cylinder Bore ◽  
Cylinder Bore Distortion

This study investigates the potential factors which may cause cylinder bore distortion in V6 aluminum engine block with cast-in gray iron liners. In this research, the microstructure, mechanical properties and residual stress of 319 type aluminum alloy engine blocks were analyzed from top to bottom along the interbore regions in the TSR, T7 heat treated and service (dyno) tested conditions. The results suggest that the cooling rate increased significantly along the cylinder in the vicinity of the chill plate at the bottom of the engine block. This caused a significant refinement in the microstructure which increased the hardness and tensile strength at the bottom of the cylinder relative to the top. The increased strength at the bottom of the cylinder prevented the rapid relief of residual stress at elevated temperature, which suggests that the bottom of the cylinder is less susceptible to cylinder distortion.

scholarly journals A Study Of Cylinder Bore Distortion In V6 Aluminum Alloy Engine Blocks

2021 ◽  
Author(s):  
Anthony Lombardi
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Gray Iron ◽  
Engine Block ◽  
Heat Treated ◽  
Potential Factors ◽  
Engine Blocks ◽  
Increased Strength ◽  
Cylinder Bore ◽  
Cylinder Bore Distortion

This study investigates the potential factors which may cause cylinder bore distortion in V6 aluminum engine block with cast-in gray iron liners. In this research, the microstructure, mechanical properties and residual stress of 319 type aluminum alloy engine blocks were analyzed from top to bottom along the interbore regions in the TSR, T7 heat treated and service (dyno) tested conditions. The results suggest that the cooling rate increased significantly along the cylinder in the vicinity of the chill plate at the bottom of the engine block. This caused a significant refinement in the microstructure which increased the hardness and tensile strength at the bottom of the cylinder relative to the top. The increased strength at the bottom of the cylinder prevented the rapid relief of residual stress at elevated temperature, which suggests that the bottom of the cylinder is less susceptible to cylinder distortion.

Simulation of Mold Filling and Solidification on Gravity Casting of Al-Si Alloy (A357)

2008 ◽  
Vol 575-578 ◽  
pp. 1204-1209
Author(s):  
Guo Fa Mi ◽  
Heng Tao Zhao ◽  
Kuang Fei Wang ◽  
Zhi An Xu ◽  
Ji Tai Niu
Keyword(s):  
Solidification Process ◽  
Mold Filling ◽  
Simulation Software ◽  
Temperature Fields ◽  
Al Alloy ◽  
Alloy Sample ◽  
Gravity Casting ◽  
Solidification Processes ◽  
Feeding Process ◽  
Filling And Solidification

The temperature at specific positions was measured by multi-channel data acquisition system in order to understand the solidification and feeding process of the sample. The Olympus metallurgical microscope was used to observe the macrostructure of the casting and analyze the freezing mechanism. The mold filling and solidification processes of the Al-alloy sample were studied by using the commercialized simulation software Z-Cast. And the simulated result was compared with the results of practical pouring test. When preheat temperature of mold is low, the pouring temperature should be higher in order to ensure completely filling of mold. As a result the solidification of sample could be feeding effectively, and the shrinkage on the upper end of sample could be eliminated. It is shown that the casting simulation software Z-CAST can be used to simulate the filling and solidification process of gravity cast Al alloy and can provide exact flow fields and temperature fields thus can predict cast defects and their positions.

Study on Pressure Variations in the Mold of Magnesium Alloy Die Castings

2007 ◽  
Vol 353-358 ◽  
pp. 1614-1616
Author(s):  
Yan Gai Liu ◽  
Zhao Hui Huang ◽  
Hao Ding ◽  
Ming Hao Fang ◽  
Shou Mei Xiong
Keyword(s):  
Magnesium Alloy ◽  
Real Time ◽  
Time Pressure ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Mold Filling ◽  
Die Casting Process ◽  
Die Castings ◽  
Filling And Solidification

High pressure die casting is the most common method in making magnesium alloys for both auto parts and 3C products. Pressure variations in the mold during mold filling and solidification process have direct influences on the quality and properties of die castings. In this paper, a cylinder head cover was produced to experimentally study pressure variations in the mold during magnesium alloy die-casting process in real time for the first time. Pressure varies at different positions in the mold during die casting process. This study indicates that mold filling and solidification process of magnesium alloy die castings can be described by pressure curves obtained by pressure measurement at different test positions in the cavity in real time.

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