Journal articles: 'Die casting design'

1

Waghmare, S. N., C. N. Sakhale, M. S. Giripunje, and V. M. Sonde. "Design of Pig Casting Machine." International Journal of Engineering and Technology 2, no. 6 (2010): 586–71. http://dx.doi.org/10.7763/ijet.2010.v2.186.

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Jiang, Yan, Yong Su, Ping Hu, and Wen Ping Chen. "Die Casting Mold Design of Auto Oil Pump Bracket." Advanced Materials Research 652-654 (January 2013): 2460–64. http://dx.doi.org/10.4028/www.scientific.net/amr.652-654.2460.

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This paper introduces a die-casting mold design process. On the basis of the shape of Car oil pump support, central of castings’ side face was selected as the mold joint; due to the design requirements of pouring system, we chosen bias running system. Castings’ size was calculated by requirement of die casting machine, then accomplished designs of molding and structure’s components. Because through holes which on the side face of castings are not deep, angular pin core puller is competent, at last, the final assembly of the mold and the simulation is completed.

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Zhengwuvi, L. B., and A. O. Akii Ibhadode. "Risering of a Four-Cavity Die Production Mould by Convectional Method." Advanced Materials Research 62-64 (February 2009): 664–70. http://dx.doi.org/10.4028/www.scientific.net/amr.62-64.664.

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This paper demonstrates the possibility of developing skill in producing sound metal casting from a four-cavity die production mould by assessing the riser design criteria and the castings. The assessment takes into account the location of the casting’s hot spots, casting modulus, liquid metal mass in the risers and the principle of directional solidification. The mould flask is oriented in such a way that a riser is placed directly on top of the casting’s hot spots for proper feeding during solidification. The assessment result of casting modulus shows that the feeder modulus Mf = 5.85 x 10-3 M and the casting hot spot modulus Mh = 1.88 x 10-3 M .The assessment result of castings solidification time shows that the castings solidify within 12 seconds while the feeders solidify within 30 seconds. From the assessment results it is observed that the risers hold liquid metal, feed the castings to full solidification and solidify later than the castings which they feed. Examinations at the cross sections of the finished castings revealed the absence of void formation which is a clear indication of effective and functional risers. Thus, the risers have achieved the desired requirement.

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Groneck, D., and D. Harmon. "Design Development of Unitized Titanium Structure." Journal of Engineering for Gas Turbines and Power 125, no. 1 (2002): 252–56. http://dx.doi.org/10.1115/1.1494099.

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Traditional airframe primary structure is fabricated from wrought product forms that are transformed by machining, forming, and joining into structural components. These individual parts are assembled together by fasteners to create the airframe. Significant cost and cycle-time savings can be achieved by switching from multipiece builtup assembly to a single-piece net shape casting. The reduction in number of discrete parts provides a significant reduction in both direct and indirect costs. In particular, the inherent low material costs and excellent producibility characteristics of cast metallic parts may provide a significant contribution to the goal to reduce acquisition costs. Under the program reported herein, and in conjunction with a casting vendor, prototype titanium (Ti-6Al-4V) cast airframe components were designed and fabricated. The typical overall dimensions of each casting are 50inches×40inches×30inches, and weigh approximately 190 pounds per casting. The castings were modeled on generic aircraft fuselage structure, that incorporated smooth inner moldline surface and integral webs and keels, capped by a T-element, web stiffeners, access holes, and other detail features. Multiple castings are joined to create the airframe structure. A rapid prototyping method was utilized to create the pattern, which eliminated the requirement for expensive metal tooling. The prototype castings successfully demonstrated the producibility of this generic airframe structure.

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Mao, H. K., H. Xu, and L. Xue. "Automotive Riser System Design Technology Based on CAE." Advanced Materials Research 215 (March 2011): 344–50. http://dx.doi.org/10.4028/www.scientific.net/amr.215.344.

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For the sake of achieving the feeding system to be automated designed, the automatic merging model of the casting hot spot set up based on Casting CAE, and based on this model the riser and cold-iron designs can automatically be completed. The CAD/CAE software system was developed for the steel casting, and the feeding system of the side frame casting was designed by the software. according to the process parameters that were provided in the paper, the sample casting was poured and dissected to determine the volume of shrinkage cavity of sample castings. The results showed that no shrink defect exists in the casting, so it proved that the model was reliable for the riser and cold iron design.

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Zhang, H. G., P. D. Webster, and T. A. Dean. "Computer Aided Design of Feeders for Castings." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 208, no. 4 (1994): 279–87. http://dx.doi.org/10.1243/pime_proc_1994_208_089_02.

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This paper describes a software module, contained within a design-for-casting package, which aids the user in designing efficient feeding systems for castings. The user can choose a shape suitable for a particular casting condition from a file containing a variety of feeder head types. The feeder heads are placed relative to the casting in positions appropriate to hot spots identified by a ‘heat centre’ module within the package. The number and size of heads are chosen with the aid of built-in rules that aid the user. The module provides a rationale for people, both skilled and unskilled, who have to design for casting. The validity of the design rules and guidelines within the module is demonstrated by casting three widely different shapes with and without feeders.

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Rengsomboon, A., S. Luankosolchai, N. Moonrin, et al. "I-4 INVESTIGATION OF ALTERNATIVE DESIGN OF INVESTMENT CASTING SYSTEM(Session: Casting/Molding)." Proceedings of the Asian Symposium on Materials and Processing 2006 (2006): 150. http://dx.doi.org/10.1299/jsmeasmp.2006.150.

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Cho, In Sung, Jeong Tae Kim, and Jeong Kil Choi. "Integrated Database Development for Casting Design and its Application to Casting Simulation." Materials Science Forum 783-786 (May 2014): 2142–47. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.2142.

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Development of integrated database including casting shapes with their casting design, technical knowledge, and thermophysical properties of the casting alloys were introduced in the present study. For the shape database, a number of casting products are scanned by using by using industrial computer tomography and compiled to the shape database. Each shape data in the database has also parametric 3D modeling data, not only the product but also its casting design. If casting engineer want to design new casting, similar casting shape with casting design can be easily retrieved from the shape database, and easily modified and adapted to the new casting. Technical knowledge of the various casting processes and their manufacturing process of the castings were compiled and the search engine for the knowledge was developed. Database of thermophysical properties of the casting alloys were obtained by the experimental study or calculation based on CALPHAD approach, and the properties were used for the in-house computer simulation of casting process. The databases were linked with intelligent casting expert system developed in e-design center, KITECH. It is expected that the databases can help non casting experts to devise the casting and its process. Various examples of the application by using the databases were shown in the present study.

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Khan, Muhammad Azhar Ali. "Simulation Based Mold Design Optimization of a Spring Flap Casting." Solid State Phenomena 305 (June 2020): 178–84. http://dx.doi.org/10.4028/www.scientific.net/ssp.305.178.

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The complex nature of metal casting process brings about a need to simulate it before undertaken in a foundry. Casting simulations provide insights on flow of molten metal within the mold, solidification sequence, nature and location of defects etc. Moreover, mold design can be optimized to minimize defects without undergoing physical trials-and-errors as previously practiced in traditional metal casting. This study is based on casting an ASTM A216 WCB steel spring flap for automotive suspension system using a simulation based optimized mold design. The initial and optimized mold designs are simulated in MAGMASoft for mold filling, solidification, stress distribution and defects prediction. The results of simulations and actual castings are found to be in good agreement. It is concluded that simulations are accurate in modeling casting process and in predicting defects followed by their minimization through mold design optimization. The use of auxiliary components in a carefully designed mold can lead to a nearly defect-free and high quality cast product.

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Fu, Li Bin, and Jun Yang. "Design and Optimization of Bolster Casting Process." Advanced Materials Research 482-484 (February 2012): 692–96. http://dx.doi.org/10.4028/www.scientific.net/amr.482-484.692.

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The low-pressure casting method has been used to the foundry process of bolster. According to the structural characteristics of the cast and the design process of low-pressure casting, the process programs had been accomplished. Through comparing the advantages and disadvantages of several group programs by computer simulation, after determining the initial process program, we optimized the casting process according observing the processes of cast filling and solidification by the computer simulation process of running castings. The risers and chills are very important. The contraction area of cast appears on the large flat, and the risers had been set on the large flat. This can not only play the role of feeding but also have the function of scavenging action.

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Majerník, Ján, Monika Karková, and Ján Kmec. "Assessment of Suitability of the Design of Gating System with the Use of Simulation Software." Key Engineering Materials 756 (September 2017): 136–41. http://dx.doi.org/10.4028/www.scientific.net/kem.756.136.

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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.

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Zhang, Xiu Mei, Hui Jun Jia, Di Cui, and He Liang. "Numerical Optimization Design on Coating of EPC Steel Casting." Advanced Materials Research 148-149 (October 2010): 707–10. http://dx.doi.org/10.4028/www.scientific.net/amr.148-149.707.

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Expandable Pattern Casting (EPC) technology has been more and more extensively applied to the production of steel castings in many countries, which brings outstanding economic and social benefits. Applying the best quality coating is one of the key measures to guarantee casting surface quality. Based upon experiments made for many times, the orthogonal experiments of five factors and four levels are adopted to optimize coating working properties and processing properties. Tested by practice, the coating performance indicators of intensity, permeability, coating property, dropping amount and flowing flat property reach a perfect state, which provided a reliability assurance to product sound castings.

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Majerník, Ján, Monika Karková, and Ján Kmec. "Issue of Design Gate Dimensions and Experimental Assessment of the Suitability of Analytical Design." Key Engineering Materials 756 (September 2017): 142–48. http://dx.doi.org/10.4028/www.scientific.net/kem.756.142.

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From the point of view of its design solution, the shape, the dimensions and the position of an gate have the biggest impact on the final quality of castings. The gate is where the stream of hot-melt flowing into the mould cavity is modulated, and where the speed of this stream changes, which eventually determines the loading mode of the mould cavity affecting the homogeneity of any casting, and thus its mechanical properties as well. The length of the gate for a specific type of casting is determined constantly according to the projection methodology for connecting the gate to the casting. The gate height is determined by its area to length ratio. In practice, several methods are used to determine the gate area. The presented paper deals with an assessment of particular methods of designing the gate area for a specific type of a lightweight casting on the basis of silumin produced, using die casting technology. Since the length of the gate is constant, based on particular methods for determining the area, the gate height is the variable parameter. The performed experiments focus on an assessment of permanent deformation of parts cast at certain gate heights, determined analytically according to particular calculation methods. Permanent deformation serves as an indicator of the most suitable method for the gate area calculation. At the same time, the paper specifies patterns required for the calculation of gate dimensional characteristics, since the available scientific literature only provides indicative values depending on the nature of any given casting or an alloy.

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Jia, Zhi Xin, Ning Bo Hu, Ji Qiang Li, Li Jun Liu, and Li Qiong Chen. "Die-Casting Die Design Based on the Application of CAE Simulation." Applied Mechanics and Materials 201-202 (October 2012): 541–44. http://dx.doi.org/10.4028/www.scientific.net/amm.201-202.541.

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High pressure die casting is a high volume component manufacturing process which is used extensively in many aspects. There are many factors affecting the quality of die-casting die. In this paper, the CAE simulations of filling and solidification processes for die-casting are studied. Numerical analyses are presented for two practical die-casting parts using HZ CAE software. The temperature distributions and filling states in solidification and filling process are presented. Then the deficiencies of the part are predicted. Based on the analyzing results, the structures of the two dies are optimized and longer die service life and high-quality castings are obtained. It is proved that CAE simulation results can offer a helpful reference for die-casting die design.

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Wang, Xue Dong, Jian He Lin, Suo Qing Yu, and Li Yong Ni. "Casting Mold Designing for Aluminum Alloy Car Holders." Applied Mechanics and Materials 378 (August 2013): 350–54. http://dx.doi.org/10.4028/www.scientific.net/amm.378.350.

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The structure and processing of car holders castings were analyzed. Die-casting molding process scheme was established. The design of mold includes three core-drawing mechanisms. the gate of the gating system was arranged on the casting bottom surface. For economy and die easy maintenance considerations, die-casting machine, mold, and mold standard parts should be standard parts. The designs of mold gating system and non-standard pieces were completed with the aid of PROE. Proved by actual production, the mold operated smoothly, without clamping stagnation, and the production of die castings meet delivery requirements.

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Khare, Manu, and Deepak Kumar Deepak Kumar. "Optimization of Sand Casting Parameters using Factorial Design." International Journal of Scientific Research 3, no. 1 (2012): 151–53. http://dx.doi.org/10.15373/22778179/jan2014/49.

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17

Polyakov, S., O. Kuzyi, A. Korotschenko, V. Korovin, and J. Bast. "Computer-Aided Design of Steel Casting Taking into Account the Feeding Ability." Archives of Foundry Engineering 16, no. 1 (2016): 49–54. http://dx.doi.org/10.1515/afe-2016-0002.

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Abstract A new Computer-Aided Design approach is introduced for design of steel castings taking into account the feeding ability in sand moulds. This approach uses the geometrical modeling by a CAD-program, in which the modul “Castdesigner” is implemented, which includes the feeding models of steel castings. Furthermore, the feeding ability is guaranteed immediately during the design by an interactive geometry change of the casting cross section, so that a directional feeding of the solidifying casting from the installed risers is assured.

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18

LIOU, S. Y., and R. A. MILLER. "Design for die casting." International Journal of Computer Integrated Manufacturing 4, no. 2 (1991): 83–96. http://dx.doi.org/10.1080/09511929108944483.

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Liao, Dun Ming, Li Liang Chen, Jian Xin Zhou, and Rui Xiang Liu. "CAD/CAE Technology and its Application on Nonferrous Alloy Casting." Advanced Materials Research 139-141 (October 2010): 1113–16. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.1113.

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The nonferrous alloy castings will be much demanded with the development of aerospace, light-weight weapons and automotive industry. Casting CAD/CAE technology has played an increasingly important role in foundry. It can help technician to design casting process and simulate heat transferring and molten metal flowing before actual production. Firstly, the main contents and basic principles, mathematical models of casting CAD and CAE were introduced. Secondly, the casting CAD/CAE technology route was interpreted, and then several CAD/CAE applications of casting process design and simulating were carried out on nonferrous alloys, such as aluminum, magnesium and copper. The results indicate that CAD/CAE technology can be applied to casting process design and predict casting defects which usually occur during the casting mold filling and solidification process, it can provide references to optimize casting process, so as to improve casting quality, reduce the rejection rate and shorten the development cycle of new products.

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Wang, Ao Bing, Xue Dong Wang, Zheng Dong Chen, Li Yong Ni, and Xiao Qin Gu. "Casting Mold Designing for Double-Chamber Throttle Valve." Advanced Materials Research 787 (September 2013): 445–49. http://dx.doi.org/10.4028/www.scientific.net/amr.787.445.

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The structure and processing of double chamber throttle valve body castings were analyzed. Die-casting molding process scheme was established. The design of mold includes three core-drawing mechanisms. Considering the large parts surface area and the relatively small wall thickness and the requirement of parting, the gate was arranged on the casting bottom surface. For economy and die easy maintenance considerations, die-casting machine, mold, and mold standard parts should be standard parts. The designs of mold gating system and non-standard pieces were completed. Proved by actual production, the mold operated smoothly, without clamping stagnation, and the production of die castings meet delivery requirements.

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Huang, Pei-Hsing, Jenn-Kun Kuo, Te-Hua Fang, and Wei-ren Wu. "Numerical simulation and design of casting system for stainless steel exhaust manifold." MATEC Web of Conferences 185 (2018): 00008. http://dx.doi.org/10.1051/matecconf/201818500008.

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During operation, exhaust manifolds must bear the corrosion of high temperatures and repeated stress, which can easily lead to cavitation, corrosion, and creeping damage in the casting structure and affect product safety. To improve the structure of exhaust manifolds and increase their service life, we employed AnyCasting mold flow analysis to SUS304 stainless steel exhaust manifolds. We examined the influence of casting system design and process parameters such as ceramic shell temperature, casting temperature, and pouring speed on the filling and solidification processes of the liquid metal. Finally, we used the Niyama criterion to predict the probability and distribution of shrinkage porosity defects in the exhaust manifold and made improvements to enhance the quality of exhaust manifold castings. Keywords: exhaust manifold, mold flow analysis, casting system.

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Tang, Jin Jun, Li Qun Hou, Liang Jun Fei, Yu Lei Li, and Xiao Yu Jin. "Air Conditioning Compressor Front Cover of Squeeze Casting Process Design and Numerical Simulation." Applied Mechanics and Materials 602-605 (August 2014): 209–13. http://dx.doi.org/10.4028/www.scientific.net/amm.602-605.209.

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This paper is mainly on the research of squeeze casting production automobile air conditioner front cover FS170C, due to the development and optimization of the part in the production process, design and manufacture of low cost mould, the rules of structure and properties of castings is lack of corresponding research, seriously affected the development and market competition ability of the air conditioning compressor front cover. In order to solve the above problems, and to provide reference data and process scheme is necessary, this study to optimize the design of squeeze casting technology of the front cover of the air conditioner, finalized a most reasonable extrusion casting scheme, namely the gating system is more suitable and exhaust system design, and the squeeze casting process parameters, in this scheme next, carries on the mold design, production of squeeze casting of high quality.

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Ragab, Khaled A., Mohamed Bouazara, Amine Bouaicha, and Hatem Mrad. "Materials Performance and Design Analysis of Suspension Lower-Arm Fabricated from Al-Si-Mg Castings." Key Engineering Materials 710 (September 2016): 315–20. http://dx.doi.org/10.4028/www.scientific.net/kem.710.315.

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The diversity of physical and mechanical properties of aluminum alloys leads to develop a variety of manufacturing processes including the semi-solid casting process. Fatigue failure is considered the most common problem occurred in automotive engineering applications by which the vehicle components, mainly suspension system parts, fail under conditions of dynamic loading. It is well known that the fatigue life of aluminum castings, mainly A357, is very sensitive to casting design as well as to casting defects and microstructure constituents. The fatigue characteristics of automotive lower suspension arm made of semi-solid A357 aluminum castings have been investigated using metallurgical and analytical approaches. The critical stress areas capable of initiating cracks during fatigue tests are detected by using fatigue experimental design for real part materials by the installation of strain gages on the suspension arm to calculate maximum stress; further more, analytical approach is applied using modelling software. Microstructure characteristics of the semisolid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that using the SEED casting technology (Swirled Enthalpy Equilibration Device) has an efficient effect on the mechanical and metallurgical characteristics of real part materials that are also affected by castings design.

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Huang, Pei Hsing, Wei Jen Wu, and Chung Han Shieh. "Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels." Applied Mechanics and Materials 864 (April 2017): 173–78. http://dx.doi.org/10.4028/www.scientific.net/amm.864.173.

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The lightweight design of aluminum automobile wheel can easily bring about all kinds of defects during die-casting, which often causes wheel frame deformation and creep damages in the future use and in turn affects traffic safety. To understand the evolution of mold flow, temperature field, and solidification, the low pressure die-casting processes of A356 aluminum wheel were simulated by Anycasting software package. Various casting parameters combined with the designs of flow channel and overflows were adopted to reduce the defects occurred in wheel products. In addition, we adopted the retained melt modulus (RMM) to predict the position of defects to be formed as well as their distribution so as to eliminate the shrinkage voids and porosity defects during die-casting. The research findings showed that the setting up of overflow tank could effectively prevent the formation of shrinkage void and porosity of die-castings and significantly promote the quality and productivity of die-casting wheel products.

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Tang, Hong Tao, Li Li, Lang Huang, and Shun Sheng Guo. "A New Process CAD Design Method for Steel Casting Based on PDF File." Advanced Materials Research 1049-1050 (October 2014): 2100–2104. http://dx.doi.org/10.4028/www.scientific.net/amr.1049-1050.2100.

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The process CAD design is the key part for steel casting production in general foundry enterprises. Formerly, for those parts with PDF file from customers, especially foreign customers, the process CAD design was done just by 2D casting process CAD system depending on AutoCAD system; so the designer must spend much time drawing part by AutoCAD according the PDF file which cause low efficiency. In this paper, a new process CAD design method is proposed based on PDF file in order to avoid drawing part by AutoCAD. Fist, the framework of process CAD design is constructed. Second, as the base part of process CAD design, the practical 2D CAD frame is established. Third, the part drawing with PDF file is resolved to be displayed clearly through the Mupdf rendering engine. Finally, the casting processes design of two actual steel castings, including a pump cover casting and a large gear casting, are presented to illustrate this new process CAD design method.

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Gašpár, Štefan, Tomáš Coranič, Ján Majerník, et al. "Influence of Gating System Parameters of Die-Cast Molds on Properties of Al-Si Castings." Materials 14, no. 13 (2021): 3755. http://dx.doi.org/10.3390/ma14133755.

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The resulting quality of castings indicates the correlation of the design of the mold inlet system and the setting of technological parameters of casting. In this study, the influence of design solutions of the inlet system in a pressure mold on the properties of Al-Si castings was analyzed by computer modelling and subsequently verified experimentally. In the process of computer simulation, the design solutions of the inlet system, the mode of filling the mold depending on the formation of the casting and the homogeneity of the casting represented by the formation of shrinkages were assessed. In the experimental part, homogeneity was monitored by X-ray analysis by evaluating the integrity of the casting and the presence of pores. Mechanical properties such as permanent deformation and surface hardness of castings were determined experimentally, depending on the height of the inlet notch. The height of the inlet notch has been shown to be a key factor, significantly influencing the properties of the die-cast parts and influencing the speed and filling mode of the mold cavity. At the same time, a significant correlation between porosity and mechanical properties of castings is demonstrated. With the increasing share of porosity, the values of permanent deformation of castings increased. It is shown that the surface hardness of castings does not depend on the integrity of the castings but on the degree of subcooling of the melt in contact with the mold and the formation of a fine-grained structure in the peripheral zones of the casting.

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Maharajan, B., and Dr S. Balasubramanian. "Design and Analysis Fixtures for Aluminium Die Casting Component." International Journal of Innovative Research in Computer Science & Technology 5, no. 4 (2017): 306–12. http://dx.doi.org/10.21276/ijircst.2017.5.4.2.

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Jiang, Meng, Yang Yang, and Hong Feng Zhang. "Design of Time-Lapse Core-Pulling Mechanism with Side Slide in Die-Casting Die." Advanced Materials Research 557-559 (July 2012): 1235–38. http://dx.doi.org/10.4028/www.scientific.net/amr.557-559.1235.

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In the process of die-casting die design, the die castings should be usually left in the moving die in order to design ejecting mechanism conveniently when open mould. For the special structure of die castings, when lateral side core-pulling mechanism and larger wrapping force on the fixed-die core than on the moving-die core are required, the time-lapse core-pulling mechanism with side slide block can be adopted, which can make die castings left in the moving-die after open mould, and assure die castings production to do successfully. Time-lapse core-pulling mechanism with side slide block is ingenious and simple, and doesn’t increase the production cost of die casting die, and has certain reference value to the design of it.

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Shang, Shu Zhen, Jiao Jiao Wang, Gui Min Lu, and Xiao Ling Tang. "Study on the Semi-Solid Thixo-Diecasting Process of Aluminum Alloys and Die Design." Solid State Phenomena 192-193 (October 2012): 460–65. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.460.

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The constitutive equation of semi-solid 6061 alloy was established according to the thermal simulation compression tests of semi-solid billet of 6061 alloy prepared by near-liquids semi-continuous casting method. Parameters of Bingham model, such as apparent viscosity, had been investigated based on the constitutive equation of semi-solid 6061 alloy. The software ANYCASTING was applied to simulate and analyze the semi-solid die-casting processes of semi-solid 6061 alloy. A well-designed runner and gating system of automobile aluminum alloy part were presented and the casting defect were investigated here utilizing these parameters by simulation. The results show that a well-designed runner and gating system is very important to secure good quality die castings through providing a homogenous mould filling pattern. Most defects of semi-solid casting products can be founded in the final solidification of the parts of casting.

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Ignaszak, Zenon, Jakub Hajkowski, and Paweł Popielarski. "Mechanical Properties Gradient Existing in Real Castings Taken into Account during Design of Cast Components." Defect and Diffusion Forum 334-335 (February 2013): 314–21. http://dx.doi.org/10.4028/www.scientific.net/ddf.334-335.314.

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The problem concerns the structure and properties heterogeneity of cast products, on the example of the Al-Si (A356) alloy. The trends of usage of this knowledge by constructors of that kind of products are described in this paper. It is well known that soundness of cast products is a postulate formulated by designers and users of machines and devices, where castings are among important parts. It is often forgotten though, that perfect soundness (density) of the cast material in ready for use parts simply does not exist. The gas and shrinkage porosities, present in semi-finished casting products, obtained from a liquid state of an alloy is the result of phenomena occurring during multiphase metallic system crystallization. Still, general introduction of thetolerance of damagerule requires knowledge about casting technology, inspection of the state of discontinuity of casting structure. The use of coupled experimental researches (including NDT non-destructive testing and local mechanical properties of castings) and simulation tests (Procast, ANSYS) have shown how the properties gradient influences on the safety factor distribution in the casting subjected by chosen load.

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Zhao, Wan Jun, Zheng Hua Deng, and Hua Ju Teng. "Structural Optimization Design for Lower Beam of Hydraulic Press with the Casting Process Requirement." Advanced Materials Research 655-657 (January 2013): 386–89. http://dx.doi.org/10.4028/www.scientific.net/amr.655-657.386.

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Through combining with VC++ and APDL language of ANSYS, the finite element optimization design for lower beam of the YJ32 hydraulic press was completed used complex method. The global optimum solution was obtained in the case of meeting the casting process requirement. The casting process requirement is that the thickness of a casting is almost the same and the inner wall thickness should be a little smaller than the outside wall thickness. The optimal result reduces the structure weight and the cost of the lower beam. Meanwhile, this provides a new method for the finite element optimization design about castings.

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Dong, Yi, Xiao Ming Fan, and Bin Liu. "Numerical Simulation and Technology Optimization of Rear Oil Seal Bearing Die Castings Based on ProCAST." Advanced Materials Research 189-193 (February 2011): 4008–13. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.4008.

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In production,the Φ105 mm hole of rear oil seal bearing die castings often appear porosity, shrinkage and other defects , resulting in the parts to scrap. The existing gating system design of rear oil seal bearing die castings was improved , and the flow and temperature field of the two programs that before and after improvement were analyzed by ProCAST software. The simulation results predicted the casting defects, and the conclusion was consistent with the production. By using the improved process optimization, the rejection rate of die castings can be reduced effectively. Die casting is a chipless forming of casting with high casting dimensional accuracy, high surface quality and high production efficiency [1,2]. Therefore, it has developed rapidly in the automotive, communications and other industries. However, due to shrinkage, porosity and other reasons, leading to high rejection rate of castings. With the emergence of commercial casting simulation software, the casting production has been developed from semi empirical and semi theoretical onto theorization, quantification and controllable track[3-5]. In this paper, the casting defects of rear oil seal bearing is analyzed by using numerical simulation technology[6]. By optimizing the casting process, the casting quality is improved, and the rejection rate is reduced effectively.

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Papanikolaou, Michail, Emanuele Pagone, Konstantinos Georgarakis, Keith Rogers, Mark Jolly, and Konstantinos Salonitis. "Design Optimisation of the Feeding System of a Novel Counter-Gravity Casting Process." Metals 8, no. 10 (2018): 817. http://dx.doi.org/10.3390/met8100817.

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The appropriate design of feeders in a rigging system is critical for ensuring efficient compensation for solidification shrinkage, thus eliminating (shrinkage-related) porosity and contributing to the production of superior quality castings. In this study, a multi-objective optimisation framework combined with Computational Fluid Dynamics (CFD) simulations has been introduced to investigate the effect of the feeders’ geometry on shrinkage porosity aiming to optimise casting quality and yield for a novel counter-gravity casting process (CRIMSON). The weighted sum technique was employed to convert this multi-objective optimisation problem to a single objective one. Moreover, an evolutionary multi-objective optimisation algorithm (NSGA-II) has been applied to estimate the trade-off between the objective functions and support decision makers on selecting the optimum solution based on the desired properties of the final casting product and the process characteristics. This study is one of the first attempts to combine CFD simulations with multi-objective optimisation techniques in counter-gravity casting. The obtained results indicate the benefits of applying multi-objective optimisation techniques to casting processes.

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Hojjat Majidi, Seyyed, Christoph Beckermann, Jakob Fainberg, Wilfried Schäfer, and Mathias Bodenburg. "Modelling Approach and Challenges in Simulating Dross Formation in Ductile Iron Castings." Materials Science Forum 925 (June 2018): 419–26. http://dx.doi.org/10.4028/www.scientific.net/msf.925.419.

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Dross is one of the most challenging quality issues in high integrity ductile iron castings. The formation of dross is linked to the applied metallurgy, metal treatment, process control and gating/rigging design. One of the primary concerns in this regard is entrainment of air into the melt during filling of the casting. Today, avoiding and controlling dross relies on the practical experience and process know-how of foundry experts. A quantitative understanding of the formation mechanisms or the prediction of final amounts and locations of dross in castings is not available. In this paper a computational model is developed for predicting the formation, motion and final location of dross inclusions during pouring of ductile iron castings. The focus is on the important mechanism of dross generation due to air entrainment during filling of the mold. The model predicts the local air entrainment rate as a function of the turbulent kinetic energy of the liquid metal and the normal velocity gradient of the metal at the liquid metal-air interface. The dross inclusions resulting from the exposure to the entrained air are transported with the melt flow under the combined influences of drag and buoyancy, and captured by the solidifying casting structure. The model is implemented in a commercial casting simulation software code. Ductile iron casting experiments are conducted to validate the model using castings having a variety of gating systems, section thicknesses, and surface orientations. Dross is measured by serial sectioning of the solidified castings. Good agreement between measured and predicted dross amounts and locations is obtained. The results reveal how gating system design affects dross formation. Clean ductile iron castings can be obtained by minimizing air entrainment during pouring. The present model allows foundries to evaluate different gating designs and pouring parameters before the first casting is poured. The paper also discusses open issues and practical challenges in quantifying the amounts of dross as a function of the entire processing route of a casting.

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Akimov, O. V., A. P. Marchenko, V. I. Alyokhin, et al. "Computer Engineering and Design of Cast Parts for Internal Combustion Engine Crankcase." Journal of Engineering Sciences 6, no. 2 (2019): e24-e30. http://dx.doi.org/10.21272/jes.2019.6(2).e4.

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This paper discusses the formulation of the problem of designing the cast parts block-crankcases engine in order to ensure its quality for the case study of cast iron parts of the cylinder block inline four-cylinder gasoline engine with the capacity of 1.4 dm3. Material Ch190B is gray cast iron with optional chemical composition, and sulfur – no more than 0.15 %, phosphorus – no more than 0.1 %, structure – perlite plate. The results obtained in this work confirm the conclusions about the possibility of reducing the metal content of the casting and changing the technical conditions of its manufacture. According to the results of the research, the developed recommendations are aimed at stabilizing the characteristics of the metal, reducing metal consumption, and changing the technical conditions for the defectiveness of this type of castings. Recommendations for changing the configuration of the partition in order to reduce the metal content of the casting and recommendations for changing the Technical Conditions for casting defects were stated for the casting block crankcase 4ChN12/14. For defects of discontinuity type, the maximum size was defined, and controlled places of their detecting were defined. Keywords: CAD, CAE, block-crankcase, 3D model, casting defect.

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Waqar, Taha, Muhammad Azhar Ali Khan, Muhammad Asad, Faramarz Djavanroodi, and Jamal Nayfeh. "Design and Development of a Mold for Patternless Casting Using AM/3D Printing." Materials Science Forum 1033 (June 2021): 98–102. http://dx.doi.org/10.4028/www.scientific.net/msf.1033.98.

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Additive manufacturing is a technology that is influencing every facet of manufacturing such as casting. 3D printing in particular has the potential to revolutionize castings in terms of precision and time taken in production. Patternless molds increase the efficiency of the casting process for large scale manufactured components. Therefore, ceramic based molds can be utilized for low temperature alloy parts such as mounting brackets. Nowadays, 3D printing technologies allow the direct printing of these molds. This is possible with the aid of CAD modelling of the casting mold which allows instant printing of patternless molds. The aim of this work is to introduce an approach to prepare a 3D design for a casting mold that can be manufactured using 3D printing technology. Mold design was made using Solidworks software according to standardized calculations from which cope and drag components were extracted. Candidates for potential mold material are highlighted along with advantages & limitations of utilizing 3D printing methodology.

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Jarfors, Anders. "Casting Alloy Design and Modification." Metals 6, no. 1 (2016): 15. http://dx.doi.org/10.3390/met6010015.

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Ni, Li Yong, and Peng Liu. "Numerical Simulation and Production Trial of Aluminum Alloy Gear Box Housing." Applied Mechanics and Materials 703 (December 2014): 232–36. http://dx.doi.org/10.4028/www.scientific.net/amm.703.232.

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Die casting processing analysis was conducted and the gating system and the cooling system were designed for aluminum alloy gearbox housings. Numerical simulation software PROCAST was used to calculate the filling and solidification sequence and the temperature field of die castings. The reasonable designs of the gating system and the cooling system were obtained. The feasible die casting mould was designed and manufactured. Production trial showed that, casting molding effect is good, and there were not defects such as misrun, cold lap. After machining, there were not defects exceeding the allowed limited values including porosity, shrinkage, and slag inclusion in the products. The trial showed that the product mold design and die casting technology achieved the desired effect, which can realize batch production.

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Kaskani, Mehdi, and Behzad Niroumand. "On Non-Dendritic Microstructure Formation during Sand Casting of A356 Alloy." Solid State Phenomena 192-193 (October 2012): 433–40. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.433.

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The purpose of this study was to develop a new method for formation of non-dendritic microstructure during sand casting of aluminum alloys without any previous special processing. For this purpose, sand molds with three different types of running systems were designed. The first design included a traditional reverse tapered vertical sprue. The second design was similar to the first one except for a conical sand core placed inside the lower half portion of the sprue creating a narrow gap for the flow of the melt into the mold. In the third design, the core was fitted with metal chills. Molten A356 alloy was then cast from fully liquid state under gravity and centrifugal casting conditions in the molds and the microstructures of the castings were studied. The results showed that non-dendritic microstructure could be achieved by using the last design under low superheat temperature and centrifugal casting conditions. The findings can pave the way for small quantity production of semisolid castings in expendable molds.

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Pa, Pai Shan. "Design of Forming Sheet Electrodes in Electrochemical Finishing of ZDC2 Castings Surface." Materials Science Forum 532-533 (December 2006): 965–68. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.965.

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This research presents a new modus of electrochemical finishing as a finish process using an effective design of forming sheet electrode on zinc alloys beyond traditional process of die casting on the surface of castings instead of the conventional hand or machines polishing. In the current experiment, the author takes an outer shell of toy vehicle for instance; five types of design electrode are used and supplied with continuous direct current in the experiment of electrochemical finishing. For the design electrodes, a thin plate with small end radius and small wedge angle are associated with higher current density and provides larger discharge space and better polishing effect. The electrode with spherical head performs the best. The electrochemical finishing after die casting saves the need of hand or machines polishing just needs quite short time to make the surface of castings smoothing and bright. An effective and low-cost polishing of the surface of castings is presented.

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Wang, Lin, Jian Xin Zhou, Hong Tao Tang, and Dun Ming Liao. "Research and Development of Steel Casting CAD/CAE Integration Technology Based on the Neutral STEP File." Applied Mechanics and Materials 541-542 (March 2014): 524–29. http://dx.doi.org/10.4028/www.scientific.net/amm.541-542.524.

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The casting process CAD system developed based on the existing three-dimensional CAD software has many inadequacies. This paper innovatively puts forward the steel castings three-dimensional casting process CAD system based on neutral STEP file. In this study, by taking advantage of universal CAD data-exchange standard STEP format for data exchange, a practical three-dimensional CAD system was developed based on Open CASCADE Geometry Kernel. The system has the function of practical casting process modeling, including design and modeling of gating system and riser design and so forth. The system exceeded the deficiencies of the existing casting process CAD system. It resolves the foundry Enterprises dependence and limitations on the type and version of commercial 3D CAD software, enabling to realizethe integration of CAD and CAE on casting process.

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Peng, Xian Ping. "The Exploration of Appropriate Pouring Time which is the Important Parameters in Gray Cast Iron Foundry Process Design." Applied Mechanics and Materials 157-158 (February 2012): 1365–71. http://dx.doi.org/10.4028/www.scientific.net/amm.157-158.1365.

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The determination of pouring time is the important content in the casting process design. Pouring time to determine the design of the casting process is very important content. Appropriate pouring time can avoid many defects such as misrun, cold lap, entrapped slag, distortion, blowhole, swell, cope raise and so on. This paper analyzes the characteristics and shortcomings of determining several kinds of pouring time in current production of gray iron castings. The writer proposed a new calculate formula of pouring time about gray iron casting. By comparing the successful production instances, it is proved that it is good reliability, scientific and suitability.

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Chen, Song, Da Quan Li, Fan Zhang, et al. "Development of Semi-Solid Die Casting Process Technology for Aluminium Alloy Clamp." Materials Science Forum 850 (March 2016): 642–48. http://dx.doi.org/10.4028/www.scientific.net/msf.850.642.

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Compared with traditional liquid and solid processing methods, semi-solid die casting process can apparently overcome shrinkage cavity and porosity defects in castings and high deformation resistance and high residual stress shortcomings in forging parts. Semi-solid die casting process with advantages such as high efficiency and low cost, will become the optimal process for high quality automobile parts. In this study, using the clamp as an example, the author introduced product structure optimization and die design for semi-solid die-casting process of aluminum alloy in a new product development.The Computer Aided Engineering technology was applied to the product structure optimization according to the stress analysis. The optimal mold structure, including cavity layout, gating system, overflow and vent systems, were confirmed based on the die design criteria for traditional die casting, combining with the characteristics of semi-solid forming and the simulation results. The semi-solid aluminum alloy clamp parts with excellent performances were finally developed successfully by means of product structure optimization, die design, parameters optimization of die casting process, and the mechanical properties test of products.The existing parts were optimized to make them more suitable for semi-solid die casting processing. In addition, a reasonable die design specially for semi solid processing was an important guarantee for a successful semi solid product applied in industry. Computer numerical simulation was applied in product structure design for semi-solid die casting, die design, die-casting process optimization and other aspects, to shorten the development cycle of new product, reduce cost and improve efficiency.

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Wang, Cheng Jun, Tao He, Xia Yang, and Jia Sheng Chen. "Design of Three-Dimensional Parallel Vibration Casting Machine." Applied Mechanics and Materials 215-216 (November 2012): 64–69. http://dx.doi.org/10.4028/www.scientific.net/amm.215-216.64.

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In order to reduce casting defects and improve casting quality, the author has developed a three-dimensional parallel vibration casting machine based on parallel mechanism. The paper introduces the three-dimensional parallel vibration casting machine in structure composition and functional properties, the casting machine degree of freedom of excitation mechanism is calculated, its motion performance is analyzed, and the kinematics equations are established. The designed casting machine achieves support and excitation functional separation of moving parts which takes complete decoupling of hybrid mechanism 2PRRR-P (2R ) as excitation mechanism, realizing flask vibration along the X, Y, Z three directions. Test results show that, the casting machine can significantly improve casting quality, raise labor productivity, save casting raw materials, and reduce the production costs.

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Xiao, Xiao Feng, Qiong Xue, Ke Feng Xiao, and Xiao Lan Hu. "LFC Mold Development of Complex Parts with Free-Form Surface." Advanced Materials Research 228-229 (April 2011): 532–36. http://dx.doi.org/10.4028/www.scientific.net/amr.228-229.532.

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This paper has analyzed key techniques in foam mold development for Lost Foam Casting for different types of casting, which are complex box, pipe faucet junction ,wear-resisting and refractory alloy steel casting, Focused on complex castings with free-form surface, key points during whole technical route, which includes three-dimensional modeling, foamed pattern design, mold design and CNC program, have been discussed by utilizing modeling & manufacturing module on Unigraphics. Because of its perfect free-form surface functions and plentiful toolpath operations in CNC programming, Foam mold of complex casting with free-form surface has been designed, manufactured and assembled successfully for LFC, Qualified foamed pattern of vortical shell has been produced successfully. Several effective methods and experiences have been achieved by utilizing CAD/CAM technology.

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Reinhardt, Carl J., Morris Murray, and Isaac Bohlken. "High Quality Non-Ferrous Die Castings Dependence on Die Design – A Review of the Use of Die Filling and Casting Solidification Simulation Results for Successful, Effective and Practical Die Designs." Advanced Materials Research 1019 (October 2014): 143–51. http://dx.doi.org/10.4028/www.scientific.net/amr.1019.143.

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High Quality Cost Effective Die Castings rely to a large extent on successful, effective and practical die design. A review is carried out of some runner and gate designs which resulted in successful high quality castings. Some High Pressure and Gravity cast casting are evaluated. Simulation results for evaluating the impact on the flow during filling due to Runner Geometries, Gate Geometries and positions as well as venting, overflows or risers are discussed. Thermal intervention through the use of internal thermal channels are also evaluated through the use of simulation results. The paper centres on a discussion of analysis of simulation results, predicting defects which impact on some aspects of surface finish and porosity. A case study is presented showing the value of following and taking heed of lessons learnt from simulation results, to carry out die designs with reduced reliance on simulation. Index Terms: South African Foundries, High Pressure Die Casting, Computerised Fluid Dynamics Simulation, Die Design, Defect Reduction.

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Liu, Han Wu, Zhao Hui Liu, and Tian Xiang Chen. "Surface Modeling Design and Temperature Field Analysis about Air Intake Cover Based on Pro/E Software." Advanced Materials Research 291-294 (July 2011): 1237–40. http://dx.doi.org/10.4028/www.scientific.net/amr.291-294.1237.

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As an outer covering of cooling aircraft engines, the air intake cover very much effects the aerodynamic performance of the aircraft under the condition of high-speed air current striking on it. In order to improve the aircraft's aerodynamic performance, the temperature field distribution of the gypsum-based Investment casting process of the air intake cover was analyzed by ANSYS software, which the Pro/E software was used as the three-dimensional modeling software. In the modeling process with Pro/E software, three default datums must be firstly established. In the same time, it is necessary to appropriately use some temporary datums. Some functions, such as Protrusion> Use Quilt> Solid or Thin,Reorder,Redefine,Reroute, are very important to generate complex curved surfaces and entities. The results of the temperature field simulation showed that the process of filling and solidification reflected the actual casting situations, forecast possible defects in casting and defective locations of the castings, order solidification was obtained which a rising head was put close to casting heat knots and final solidification positions, and ensured the feasibility and quality of the air intake cover casting.

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Jiang, Xin, Xiaodong Hu, Hai Liu, Dongying Ju, Yoshio Fukushima, and Zhenglai. "Study on casting design and analysis of magnesium alloy wheel." Multidiscipline Modeling in Materials and Structures 17, no. 5 (2021): 882–94. http://dx.doi.org/10.1108/mmms-09-2020-0236.

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PurposeThis research establishes a suitable casting model for magnesium alloy wheel. The casting of the wheel is an element that must be considered in the design of the wheel. Casting is an important basic process and technology in the field of machinery which is widely used in production, transportation, national defense, social life and other aspects. Computer numerical simulation of the casting process can shorten the product manufacturing cycle, reduce product costs, reduce casting defects and ensure product quality. The casting material in this study is AZ91 magnesium alloy used for wheel lightweight.Design/methodology/approachLightweight research of automobile is a significant trend, and people are paying attention to the lightweight design of automobiles. Higher requirement was proposed on design and casting performance of the wheel which is an important part of lightweighting vehicle. In order to achieve better quality, the parametric studies of alloy wheel and casting are necessary. This research designs a new model of automobile wheel, to ensure energy efficiency, the wheels must be as lightweight as possible, using magnesium alloy material for lightweight.FindingsAnalysis of casting process is a very complex issue. This research based on finite element theory and actual production, designed reasonable casting model, instant filling and solidification data were obtained. Aiming at reducing casting defects, process improvement of casting riser structure was designed. On the basis of the foundation, it has important guiding significance for actual foundry production.Originality/valueThis research establish a suitable casting model for magnesium alloy wheel. Aiming at reducing casting defects, process improvement of casting riser structure were designed.

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Suranuntchai, Surasak, and Ekkachai Kittikhewtraweeserd. "Analysis of Horizontal Squeeze Casting Process for Pipe Oil Part." Advanced Materials Research 482-484 (February 2012): 154–58. http://dx.doi.org/10.4028/www.scientific.net/amr.482-484.154.

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To achieve the laminar flow filling pattern in squeeze casting processes, many literatures [1-4] have reported that ideal velocity of liquid metal passing through the ingate should be between 0.1 – 0.5 m/sec. John Campbell [1] reported that liquid metal front speed velocity should be 0.4 m/sec in order to eliminate the gas porosity inside the casting. However, such slow speed requires the higher temperature of liquid metal and die. This results in not only the longer cycle time but also a coarser microstructure of the casting. In addition, the sample castings used in the literature are simple form castings which do not reflect the real castings used in daily life. In this study, the indirect squeeze casting processes is adopted to cast a motorcycle’s component originally produced by a high pressure die casting process. Based on shape and dimensions of the casting to get the real casting out for the mass production, melt’s speed must be higher than the level reported by the literatures (around 1 m/sec). As a result, a fully laminar flow may not be achievable. This is confirmed by the primary study of the process parameters and tooling design using the casting process simulation. However, by clinging on the two principles of the squeeze casting processes; (1) minimizing the amount of entrapped air by slowly fill the cavity and (2) reducing the amount of solidification shrinkage by pressurized solidification; the casting from two processes will be casted in order to compared the micro-structure and mechanical properties.

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Kamboj, Abhishek, Sudhir Kumar, and Hari Singh. "Design and Development of Hybrid Stir Casting Process." International Journal of Applied Industrial Engineering 1, no. 2 (2012): 1–6. http://dx.doi.org/10.4018/ijaie.2012070101.

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The widespread adoption of particulate metal matrix composites (MMCs) for engineering applications has been hindered by the high cost of producing components of complex shape. Casting technology may be the key to overcoming this problem with stir casting. But the problem arises with stir casting is wettability and porosity. To overcome the problem of porosity a hybrid casting process is needed. So, hybrid stir casting process was developed to produce a silicon carbide particulate aluminum alloy composite. In this paper, the authors have discussed the various parts like Muffle Furnace, Thermocouple, Electric motor Impeller & Stirrer, Crucible, Vacuum pump, Nitrogen gas, and Lifting mechanism of the Hybrid Stir Casting process.

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Journal articles on the topic 'Die casting design'

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