Papers by Keyword: Filling Process

Abstract: The traditional method has been used to the foundry technique for the melt block mobile plate. The pouring position,the parting face and some of the casting parameters were determined, such as the allowance for finish, stripping taper, the rate of shrinkage and soon on. The commercial casting simulation software was introduced into the casting process, the filling and solidification process were calculated by it. The results shown that there are some shrinkage exists in the original technique and the filling process were inordinate. The gating system was optimized and according to the simulation results, the shrinkages in the original technique were eliminated and the filling process is smoothly which could help the designer to make a correct determination.

Abstract: Oil pump cover, as a part of the oil pump, is generally formed by adopting aluminum die casting molding, and required for good internal and external quality. In order to improve the oil pump cover forming quality, the paper first simulates the thermal equilibrium of die-casting mold in the forming process by finite element analysis, and obtains the temperature curves when mold works for 10 consecutive cycles, and determines that the thermal equilibrium temperature of die-casting mold is 260 °C. And then, based on the simulation results of filling and solidification in the forming process by ProCAST software, the shrinkage and cavity appear in the larger wall thickness of the casting. Meanwhile, by simulating the die-casting processes of the oil pump at different pouring temperatures, there are the least of shrinkage and cavity when the pouring temperature setting 640 °C. The results show that: it can take some methods to achieve the progressive solidification, and can reduce or eliminate the possible shrinkage and cavity, such as shortening the distance between sprue, runner and inner runner and die casting to reduce the casting heat loss, or adding cooling system to accelerate the cooling rate in the larger wall thickness of the casting. This analysis provides theoretical basis for the actual casting production of oil pump covers.

Abstract: The rump pan is the body and the load-carry device of Scraper conveyer. the material is ZG30MnSi. In order to improve the life of the casting.this paper simulated filling and solidification process of rump pan by Procast software,and predicted the position of shrinkage cavity and shrinkage porosity in castings.Then through improving gating system and add reasonable risers, optimal process parameters scheme is got.

Abstract: In order to reduce the wear of parts caused by long-term friction, and to reduce the frequency of parts replacement, ZA alloy with low hardness and good wear resistance is chosen to replace the traditional copper alloy as the material to manufacture automotive bushing, and the semi-solid die casting is used. On this basis, the software AnyCasting is used to simulate and analyze the filling and solidification process, the filling sequence, the variation of temperature field, and the part region where defects are prone to occur in the semi-solid process. The simulation results show that under the parameters set in the simulation process, when casting filling rate reached 90%, the metal started to solidify; since the gate place is easy for heat dissipation, when the temperature of the alloy liquid reached its liquidus temperature 595°C, the phenomenon of solid-liquid phase separation appeared at the gate; the defects such as gas trapping, residual stress and deformation would appear both in the place of first filling and the parting surface; when the preheat temperature of the mold was 150°C-200°C,the alloy liquid possesses liquidity. The simulation results offer certain theoretical instruction to optimize the semi-solid casting process of ZA Alloy automotive bushing manufacturing, as well as reducing or avoiding a variety of quality defects arose in the actual casting process.

Abstract: A three dimensional incompressible gas-liquid two-phase flow model is proposed to accurately simulate the fluid flow of casting's mould filling process. The gas entrapment during mould filling is studied under different initial velocity and pressure conditions. The simulation results show that the velocity of change has a larger effect on gas entrapment, Initial velocity affects the distribution of temperature field,meanwhile gas entrapment parts specialized sampling is proceeded for qualitative detection at the scene. The simulated result is consistent with the experimental result, which can be reference for the process parameters selection and mold design of filling process in large steel-ingot. Keywords: gas entrapment, the filling process , the numerical simulation

Abstract: Free-surface phenomena play an important role in many engineering applications, such as filling process in casting, etching process and so on. As we know, level set kind method is more accurate than Volume of Fluid kind method. In this paper, we implement a hybrid lattice Boltzmann and particle level set method to simulate filling processes in a 2D cavity. Results obtained by the hybrid lattice Boltzmann and particle level set method show the same filling pattern with other methods in two different Reynolds numbers.

Abstract: Free-surface model with surface tension and wall adhesion(wetting) is a very efficient technique to simulate two-phase flows with high density and viscosity ratios, such as etching and casting processes. In this paper, a conservative surface tension and wall adhesion model based on lattice Boltzmann single-phase free-surface method is proposed. The effectiveness of the model is demonstrated by simulating the flows induced by wall adhesion and surface tension, and filling processes in a 2D cavity.

Abstract: Expected to the non-grid characteristics and pure Lagrangian properties of SPH, the simulation of casting’s filling process would be simpler and precise. In this study, the implementations of SPH method are studied for liquid metal flow and heat transfer during the filling process. The temperature based thermophysical parameters are fitted and add into flow-heat coupling program. The temperature recovery method is included to consider the effect of latent heat. The validation of one-directional heat transfer problem shows that the SPH results have good agreement with the analytical results. The maximum relative error is less than 3%. Finally a circular part is calculated and proved that the SPH model used here works well and has enough precision to capture the behavior of the filling process.

Abstract: A finite element method (FEM) has been developed to simulate the isothermal resin infusing process in resin film infusion. The FEM is based on conservation of resin mass at any instant of time and is objective of resin film infusion (RFI) fiber impregnation and mold filling. The developed computer code was able to simulate the resin infusing visually. A numerical example presented here demonstrated that compared with traditional finite element/ control-volume (FE/CV), FEM is physically accurate and computationally efficient.

Abstract: In the paper, flow status and solidification status of molten steel in inner-outer couple cooling mold in the filling process are simulated by using fluid dynamics software Flow-3d, and obtain distributing diagrams of flow field and temperature field and free-surface shape diagrams in the filling process. Influences of flow field and temperature field of filling process on solidification are analyzed in the slab continuous casting. It is indicated that inner cooler can improve molten steel flow status, which is favorable to inclusion in molten steel floating up, quicken the solidification rate of molten steel in the mold.