Papers by Keyword: Casting Process

Abstract: Kenaf fiber possesses the capability for application in bio-composite materials, owing to its appealing mechanical and physical properties. This research aimed to achieve the optimum flexural strength of kenaf fiber/epoxy bio-composites materials with variations in kenaf fiber content, curing time, and curing temperature using a casting process. This study found that kenaf fiber addition increased the flexural strength of kenaf fiber/epoxy bio-composite, by varying curing time (30, 45, and 60 minutes) and curing temperature (60, 90, and 150 °C). The results showed that the highest flexural strength was obtained at 90°C (72.5 MPa) at 20/80 kenaf fiber content, at various curing temperatures. Meanwhile, the same highest flexural strength value (72.5 MPa) was also obtained for 20/80 kenaf fiber content, 45 minutes at various curing times. SEM image shows that 20 Wt.% kenaf fiber content has a better dispersion compared with 10 Wt.% so that affects the flexural strength value.

Abstract: During the metallurgical process, per each charge, the raw material is continuous casted in order to obtain billets. The main goal of this article is to optimize the number of casted billets per charge using Linear Programming’s algorithm called Simplex. The maximisation of the number of casted billets regard to available lengths and weights has been implemented in Matlab enviroment. Using Simplex Method, the maximum number of casted pieces per charge and the number of billets for each length were achieved in order to obtain good performances, and minimum liquid steel waste.

Abstract: This paper deals with the optimization of the casted billet’s lengths, in the context of diverse received orders. Linear programming is used in order to solve the optimization problem, such that minimum cost for the optimal lengths results. A technological constraint is that the number of resulted billets for each casted length must be an integer one. The authors also propose an algorithm for determining the number of batches of liquid steel needed to cover all pieces at optimal lengths for the diverse orders, and also the scheduling order of the casting process.

Abstract: EPC process, based on the casting structure, technical requirements, production volume, production conditions determines the casting solution, process planning. In this paper, the author from three aspects , the analysis of die casting process design principles, design principles and infiltration technology, makes a deeper understanding on the EPC process, and put forward some standards and requirements of the EPC process technology, which avoid the casting defects and waste caused by technical factors.

Abstract: According to the specific structure of the hopper and cylinder of twin screw cone feeder machine, 16MnR and austenitic hopper and machine cylinder and stainless steel 1Cr18Ni9 are used for construction by welding process instead of cast steel ZG310-570 galvanized originally. The weld technology process is formulated. In the process of implementation of the program, the difficulties of the process as follows are solved: Selection the alternative materials; rational design of cooling water structures; form and position tolerances between double cone screw and inner sphere – conical surface, reduction of the difficulty of processing the double cone cambered, welding deformation control, post - weld heat treatment of removal residual stresses.

Abstract: 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.

Abstract: Two kinds of methods of casting process for shaft locking pin were introduced. Simulated and analyzed the casting process by ANYCasting. Predicted the potential defects, resulted in a relatively optimized design. Replaced the traditional trial-and-error test with computer simulation, reduced design time and improved design efficiency.

Abstract: Nowadays, most 3D casting process CAD systems are developed based on second development tools of various 3D CAD systems. However the type and version escalation of various 3D CAD systems in foundry enterprises greatly limit the application of 3D casting process CAD systems. By the data exchange between the neutral file format of 3D geometric model, these problems can be well solved. In this study, by taking advantage of universal CAD data-exchange standard iges for data exchange, a practical 3D CAD system was developed based on opencascade geometry kernel. The system has the function of design and modeling of practical casting process such as part information extraction, parting surface, gating system, riser system and so on. Finally taking a steel casting for example, the casting process is exported in the file of stl and the simulation analysis is carried by intecast software which demonstrate the system based on iges neutral file can well support the integration of casting CAD and CAE.

Abstract: In the low pressure casting process of A356 aluminum alloy wheel hub, casting defects including shrinkage cavity, shrinkage porosity, impurity and pore usually occur inside the casting. These defects affect the mechanical properties of the casting. To solve this problem, we conducted a study based on a cooperation project with a well-known domestic automobile wheel manufacturer. In the present study, uniaxial tensile test of aluminum alloy casting containing defects was simulated and analysed, and the effect of types and number of defects on mechanical properties was studied by finite element analysis software. Statistical analysis of the data was provided by the manufacturer. It has been found that the degassing technology is effective by the quantitative analysis method. Based on the analyses of experimental data and the numerical simulation it is deduced that the tensile strength of casting increases with the increase of the defects due to the presence of impurity. This was confirmed in this research project, it has been observed that the defect rate of the casting sample is reduced from 5%-6% to less than 1%.

Abstract: The casting process design and simulation of the end blade of ZLT1200 axial flow pump were presented in this paper. Three kinds of casting processes were designed and simulated using ProCAST. The 3D models of the casting processes were set up by Pro/E software. The optimized cast process was selected by simulation results. Practical production of optimized cast process was also carried out. The practical production results indicated that the selected cast process can meet the practical production demand and that end blades with high quality were manufactured.