Simulation of Centrifugal Casting via STAR-Cast. Santhanu Jana, Access e.v., Aachen

Save this PDF as:
 WORD  PNG  TXT  JPG

Size: px
Start display at page:

Download "Simulation of Centrifugal Casting via STAR-Cast. Santhanu Jana, Access e.v., Aachen"

Transcription

1

2 Simulation of Centrifugal Casting via STAR-Cast Santhanu Jana, Access e.v., Aachen

3 Talk overview Centrifugal casting STAR-Cast s modelling basis Motivation for centrifugal investment casting Centrifugal investment casting of Low pressure turbine blades Turbocharger wheels Future work

4 Introduction to centrifugal casting Centrifugal forces distributes the molten material in the mould Rotation axis may be horizontal, vertical or inclined Preferred for high quality cast parts Rolls, nozzles, wheels, jewellery, etc Casting materials: iron,steel, alloys of Aluminium, Copper, Titanium etc Top rollers Casting Bottom rollers Schematic of horizontally rotated bimetallic casting Liquid metal Mould Coating

5 Modelling basis in STAR-Cast

6 STAR-Cast s modelling approach Coupled flow and solidification model : Multi phase approach: gas, liquid and solidified metal HRIC: ensures sharp resolution of free surface, entrapped gas bubbles Porous walls: Escape of gas through shell moulds Interfacial forces: Surface tension and wetting angle effects Rotational forces : are modeled based on rotating frame of reference Moving grids: to model crucible tiling and pouring into the funnel Polyhedral meshes: for complex geometries and multiphysics simulations Material data: Comprehensive and fully documented data dedicated for casting simulation High performance computing: Scales almost linear on parallel machines down to cells per processor: STAR-Cast Power Version

7 STAR-Cast s modelling approach Advanced liquid-solid state transition model Resistance to flow is a function of secondary dendrite arm spacing Solid Mushy Liquid f L = 0.0 f L = 0.3 f L = 1.0

8 Motivation for centrifugal investment casting

9 Casting of TiAl components with centrifugal investment process Aero-engine manufacturers are introducing using new light weight materials Intermetallic TiAl alloys 50% lower weight compared to conventional Ni-based alloys. Centrifugal investment casting can deliver high quality requirements Ni basis Vs. TiAl blades

10 Near-net-shape parts manufacture of Titanium Aluminides HPC Vanes LPT Blades Turbocharger Wheel Medical Implant But a difficult material to cast Potential of misrun Components like LPT blades have trailing edges of around 0.5 mm

11 Centrifugal Investment Casting of Low Pressure Turbine (LPT) Blades

12 Typical casting defects in LPT blades Misruns Porosity Ceramic Particles Hot tearing Gas entrapments Ceramic breakouts The foundry engineer faces an uphill task!!!!

13 Centrifugal investment casting LPT Blades Separation valve (open) Heating box Tilting Induction Skull Melting Copper Crucible Melt Melting chamber Casting chamber Sprue Process characteristics Two chamber system Melting capacity: 10.0 kg (optional 25 kg) Rotation speed:0-400 rpm Mould filling in 1.5 seconds Rotation Rotating table Melt distributor

14 Simulation of the pouring process STEP 1: Simulate the crucible pouring process moving grids Metal flow Velocity field Wetting

15 Simulation of the pouring process Obtain inlet mass flow rate for the casting cluster Optimize the pouring process Funnel outflow Skull weights on funnel

16 Simulation of the casting cluster of LPT blades STEP 2: Simulate the casting cluster Generate the shell mould and mesh Apply inlet, initial and boundary conditions Use appropriate time step size (around 1.0e-4s) Solve on a high performance computing cluster (With around 72 processors total computing time is 4 days) Objectives: Predict misruns : i.e., if a fully filled blade is achievable or not

17 Typical casting cluster of LPT Blades Inlet LPT blade Distributor Ingates Rotating at 200 RPM Runner

18 Generation of shell mould and mesh Polyhedral mesh on shell mould Total mesh size :3 million cells

19 Simulations of casting cluster Rotating at 200 RPM

20 Simulations of casting cluster Rotating at 200 RPM

21 Result from Casting Trials

22 Comparison of casting trials and simulation predictions

23 Final outcome!!!! Simulations Casting designs Next time anyone flying on an aircraft fitted with these blades be assured it has been developed using state-of-the-art tool STAR-Cast

24 Centrifugal investment casting of TiAl turbocharger wheels

25 Centrifugal investment casting TiAl turbo charger wheel Centrifugal investment casting furnace, shell mold and turbocharger wheel

26 Centrifugal investment casting TiAl turbo charger wheel Process characteristics Melting capacity: 2.0 kg (max) 1 Chamber process

27 Centrifugal investment casting TiAl turbo charger wheel Ceramic shell mold calculated using the STAR- Cast shell mold generator Wrapping around parts slows down the solidification process

28 Centrifugal investment casting TiAl turbo charger wheel

29 Centrifugal investment casting TiAl turbo charger wheel spinning

30 Future work Multiple frame of references coupled with solidification Centrifugal casting of multiple alloys Particle tracking during mould filling Coupling to thermomechanics

31 Special Thanks!!

1.2 CASTING PROCESSES EXPENDABLE MOLD CASTING. Sand Casting

1.2 CASTING PROCESSES EXPENDABLE MOLD CASTING. Sand Casting Valery Marinov, Manufacturing Technology Metal Casting 5 1.2 CASTING PROCESSES Sand Casting EXPENDABLE MOLD CASTING In expendable mold casting, the mold is destroyed to remove the casting and a new mold

More information

METAL CASTING 1.1 OVERVIEW OF CASTING TECHNOLOGY. Definitions. Casting nomenclature

METAL CASTING 1.1 OVERVIEW OF CASTING TECHNOLOGY. Definitions. Casting nomenclature 1 METAL CASTING CHAPTER CONTENTS 1.1 Overview of Casting Technology Definitions Casting nomenclature Heating and pouring Solidification and cooling 1.2 Casting Processes Expandable mold casting Permanent

More information

MANUFACTURING PROCESSES

MANUFACTURING PROCESSES MANUFACTURING PROCESSES - AMEM 201 Lecture 3: Casting Technology DR. SOTIRIS L. OMIROU Manufacturing Processes - classification - CASTING FORMING Casting A manufacturing process that pours a liquid material

More information

Chapter 13 Multiple Use Casting Processes. Casting Processes. Materials Processing. MET Manufacturing Processes

Chapter 13 Multiple Use Casting Processes. Casting Processes. Materials Processing. MET Manufacturing Processes MET 33800 Manufacturing Processes Chapter 13 Multiple Use Casting Processes Before you begin: Turn on the sound on your computer. There is audio to accompany this presentation. Casting Processes Chapter

More information

Permanent Mold Casting Processes. Permanent Mold Casting Processes. Permanent Mold Casting Processes. Introduction. Permanent-Mold Casting

Permanent Mold Casting Processes. Permanent Mold Casting Processes. Permanent Mold Casting Processes. Introduction. Permanent-Mold Casting Permanent Mold Casting Processes Permanent Mold Casting Processes Economic disadvantage of expendable mold casting: A new mold is required for every casting In permanent mold casting, the mold is reused

More information

Casting of Brake Disc and Impeller from Aluminium Scrap Using Silica Sand

Casting of Brake Disc and Impeller from Aluminium Scrap Using Silica Sand Leonardo Electronic Journal of Practices and Technologies ISSN 1583-1078 Issue 10, January-June 2007 p. 145-150 Casting of Brake Disc and Impeller from Aluminium Scrap Using Silica Sand Department of Mechanical

More information

Multiple Choice Questions

Multiple Choice Questions Multiple Choice Questions 1. The metal is subjected to mechanical working for a. Refining grain size b. Reducing original block into desired shape c. Controlling the direction of flow lines 2. The temperature

More information

ALD Vacuum Technologies High Tech is our Business. TITANIUM Vacuum Precision Casting

ALD Vacuum Technologies High Tech is our Business. TITANIUM Vacuum Precision Casting ALD Vacuum Technologies High Tech is our Business TITANIUM Vacuum Precision Casting TITANIUM Vacuum Precision Casting VAR Skull Melting Cold Crucible Induction Melting Benefits of Titanium Excellent mechanical

More information

Manufacturing Processes. Casting. Associate Professor Su-Jin Kim. School of Mechanical Engineering Gyeongsang National University.

Manufacturing Processes. Casting. Associate Professor Su-Jin Kim. School of Mechanical Engineering Gyeongsang National University. Associate Professor Su-Jin Kim School of Mechanical Engineering Gyeongsang National University Outline 1. Physics 2. Sand 3. Investment 4. Die 5. Cost/Quality is a manufacturing process by which a liquid

More information

DEFINITION. Casting can be defined as the act of forming an object in a mould

DEFINITION. Casting can be defined as the act of forming an object in a mould CASTING PROCEDURES DEFINITION Casting can be defined as the act of forming an object in a mould OBJECTIVES 1. To heat the alloy as quickly as possible to a completely molten condition. OBJECTIVES. 2. To

More information

CENTRIFUGAL CASTING. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca

CENTRIFUGAL CASTING. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca CENTRIFUGAL CASTING Amit M Joshi (B.Engg. Mechanical, A.M.I.Prod.E, A.I.E) Dept. of Metallurgical Engg. & Material Science, Indian Institute of Technology Bombay, India. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca

More information

IHI CASTINGS. IHI Castings Co.,LTD. COMPANY PROFILE. URL:http://www.ihi.co.jp/ICC/ IHI Castings Co.,LTD. Akishima Head Office

IHI CASTINGS. IHI Castings Co.,LTD. COMPANY PROFILE. URL:http://www.ihi.co.jp/ICC/ IHI Castings Co.,LTD. Akishima Head Office Akishima Head Office IHI COMPANY PROFILE CASTINGS Soma Plant Soma Works, IHI Co. (full view) Matsumoto Plant IHI Shibaura Machinery Co. (full view) IHI Castings Co.,LTD. URL:http://www.ihi.co.jp/ICC/ Head

More information

Modern High Pressure Die-casting Processes for Aluminium Castings

Modern High Pressure Die-casting Processes for Aluminium Castings Modern High Pressure Die-casting Processes for Aluminium Castings M. Thirugnanam E-mail: callvmthiru@gmail.com, Mobile No. : 98402 56816 ABSTRACT There are about 33 processes commercially available for

More information

POURING THE MOLTEN METAL

POURING THE MOLTEN METAL HEATING AND POURING To perform a casting operation, the metal must be heated to a temperature somewhat above its melting point and then poured into the mold cavity to solidify. In this section, we consider

More information

Manufacturing Processes I Prof. D.B. Karunakar Mechanical and Industrial Engineering Department Indian Institute of Technology, Roorkee

Manufacturing Processes I Prof. D.B. Karunakar Mechanical and Industrial Engineering Department Indian Institute of Technology, Roorkee Manufacturing Processes I Prof. D.B. Karunakar Mechanical and Industrial Engineering Department Indian Institute of Technology, Roorkee Module - 2 Lecture - 8 Metal casting Good morning. In the previous

More information

Casting Methods. Prof. Juhani Orkas

Casting Methods. Prof. Juhani Orkas Casting Methods Prof. Juhani Orkas Overview Google Books: Handbuch für technisches Produktdesign Lost mould Permanent pattern Sand casting Manual shaping Mechanical shaping Shell moulding Ceramic moulding

More information

Chapter 11. Metal-Casting Processes

Chapter 11. Metal-Casting Processes Chapter 11 Metal-Casting Processes Summary of Casting Processes Typical Cast Parts (c) (a) (b) Figure 11.1 (a) Typical gray-iron castings used in automobiles, including the transmission valve body (left)

More information

Multiphysics CAE Simulations of Casting Process for the First Time Right Product Development

Multiphysics CAE Simulations of Casting Process for the First Time Right Product Development Multiphysics CAE Simulations of Casting Process for the First Time Right Product Development Mir Mehdi Hussain *, Ramanathan SV, and Raj C Thiagarajan *Corresponding Author ATOA Scientific Technologies

More information

Metal Casting Processes

Metal Casting Processes Metal Casting Processes Dr. N S Mahesh 1 Session Objectives At the end of the session students should have understood Fundamentals of metal casting Metal casting processes Sand casting Die casting Investment

More information

The automotive industry is moving towards expanding

The automotive industry is moving towards expanding Numerical simulation of low pressure die-casting aluminum wheel *Mi Guofa 1, Liu Xiangyu 2, Wang Kuangfei 1, Fu Hengzhi 1 (1. School of Materials Science and Engineering, Henan Polytechnic University,

More information

METAL CASTING PROCESS

METAL CASTING PROCESS METAL CASTING PROCESS 1. Permanent Pattern a. Sand casting b. Shell molding 2. Expandable pattern. a. Investment Casting b. Expanded polystyrene process (full-mold) c. Permanent mold casting process 3.

More information

Physical methods Physical Methods. Atomization Gas Atomization Water Atomization Cyrogenics Liquid Atomization Centrifugal Atomization

Physical methods Physical Methods. Atomization Gas Atomization Water Atomization Cyrogenics Liquid Atomization Centrifugal Atomization Physical Methods Atomization Gas Atomization Water Atomization Cyrogenics Liquid Atomization Centrifugal Atomization Atomization Atomization is the most important production method for metal powders. The

More information

Aluminium Foundry Practice

Aluminium Foundry Practice Aluminium Foundry Practice M Dept. of Metallurgical Engineering & Materials Science, Indian Institute of Technology Bombay (IIT Bombay), India. Email: amitjoshi@iitb.ac.in, mechamit2002@yahoo.co.uk Fabrication

More information

This chapter describes how you can model solidification and melting in FLUENT. Information is organized into the following sections:

This chapter describes how you can model solidification and melting in FLUENT. Information is organized into the following sections: Chapter 21. Melting Modeling Solidification and This chapter describes how you can model solidification and melting in FLUENT. Information is organized into the following sections: Section 21.1: Overview

More information

GLOBAL MANUFACTURING. ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ

GLOBAL MANUFACTURING. ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ GLOBAL MANUFACTURING ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ Workpiece Presentation Powder Metallurgy and Additive Manufacturing [#7] Powder Metallurgy PM parts can

More information

DIE DESIGNING AND MOLTEN METAL FLOW ANALYSIS FOR INTERMEDIATE FLANGE

DIE DESIGNING AND MOLTEN METAL FLOW ANALYSIS FOR INTERMEDIATE FLANGE Int. J. Mech. Eng. & Rob. Res. 2013 G Sureshkumar and K Maheswari, 2013 Research Paper ISSN 2278 0149 www.ijmerr.com Vol. 2, No. 4, October 2013 2013 IJMERR. All Rights Reserved DIE DESIGNING AND MOLTEN

More information

Casting Defect Analysis and Optimization Using Computer Aided Casting Simulation Technique

Casting Defect Analysis and Optimization Using Computer Aided Casting Simulation Technique Casting Defect Analysis and Optimization Using Computer Aided Casting Simulation Technique Sandeep.v. Chavan 1, Rajeev.K.Tavildar 2 M.Tech Student, Department of Mechanical Engineering, KLS GIT, Belgaum,

More information

DESIGN AND ANALYSIS OF GATING SYSTEM FOR SB-CNC TAIL STOCK BASE CASTING

DESIGN AND ANALYSIS OF GATING SYSTEM FOR SB-CNC TAIL STOCK BASE CASTING DESIGN AND ANALYSIS OF GATING SYSTEM FOR SB-CNC TAIL STOCK BASE CASTING Rohith K R 1, Rahul R 2, Liroy Oppan 3, Sheryl John 4, Amal Mohan 5, Renjith Venugopal 6, Susruthan A S 7 Bessy Paul 8, Saravanan

More information

Investment Casting Simulation

Investment Casting Simulation Investment Casting Simulation Matthias Gäumann 1) & Adi Sholapurwalla 2) 1) Calcom SA, Lausanne, Switzerland, www.calcom.ch 2) UES Software Inc., Annapolis MD, USA, www.ues-software.com In the current

More information

SOME ASPECTS OF LOW MELTING POINT ALLOY CASTINGS PRODUCTION BY TEKCAST METHOD

SOME ASPECTS OF LOW MELTING POINT ALLOY CASTINGS PRODUCTION BY TEKCAST METHOD SOME ASPECTS OF LOW MELTING POINT ALLOY CASTINGS PRODUCTION BY TEKCAST METHOD Matej BEZNÁK a, Martin BAJČIČÁK b, Roland ŠUBA c a Department of Casting, Institute of Production Technologies, Faculty of

More information

Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield

Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield Arunkumar P 1, Anand.S.Deshpande 2, Sangam Gunjati 3 1 Associate Professor, Mechanical Engineering, KLS Gogte Institute

More information

Start the Design Study!

Start the Design Study! A Design Study in Centrifugal Steel Castings Hydraulic Accumulator Cylinder for Navy Submarines Design Study Outline Introduction Design for Performance Duplex Steel Approach Alloy Selection Design for

More information

Metal Casting: Design, Materials, and Economics

Metal Casting: Design, Materials, and Economics Chapter 12 Metal Casting: Design, Materials, and Economics QUALITATIVE PROBLEMS 12.12 Describe the procedure you would follow to determine whether a defect in a casting is a shrinkage cavity or a porosity

More information

General environment. Basic structure of the machines. CAE DS Mould Design. Tampere University of Technology Tuula Höök

General environment. Basic structure of the machines. CAE DS Mould Design. Tampere University of Technology Tuula Höök General environment Tampere University of Technology Tuula Höök This chapter discusses injection molding and high pressure die casting machines. Most of the topics are important for the tool designers,

More information

A model of heat transfer in metal foaming

A model of heat transfer in metal foaming A model of heat transfer in metal foaming B. Chinè 1,2, V. Mussi 2, M. Monno 3, A Rossi 2 1 Instituto Tecnológico de Costa Rica, Costa Rica; 2 Laboratorio MUSP, Macchine Utensili e Sistemi di Produzione,

More information

Casting. Training Objective

Casting. Training Objective Training Objective After watching the program and reviewing this printed material, the viewer will learn the essentials of the various metal casting processes used in industry today. The basic principles

More information

SHORT ANSWER. Write the word or phrase that best completes each statement or answers the question.

SHORT ANSWER. Write the word or phrase that best completes each statement or answers the question. Exam Name SHORT ANSWER. Write the word or phrase that best completes each statement or answers the question. 1) A lawn roller in the form of a uniform solid cylinder is being pulled horizontally by a horizontal

More information

Prediction of Solidification Time: Chvorinov's Rule.

Prediction of Solidification Time: Chvorinov's Rule. Prediction of Solidification Time: Chvorinov's Rule. The amount of heat that must be removed from a casting to cause it to solidify is directly proportional to the amount of superheating and the amount

More information

The technology of precision casting of titanium alloys by centrifugal process

The technology of precision casting of titanium alloys by centrifugal process A R C H I V E S of F O U N D R Y E N G I N E E R I N G Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (1897-3310) Volume 11 Issue 3/2011 73 80 16/3 The

More information

Laser Cladding at Oerlikon Metco

Laser Cladding at Oerlikon Metco Nov 25 th 2014 Dr.-Ing. Thomas Peters Metco is now an important part of the Oerlikon group Red is the new Blue Metco stays Metco Page 2 Metco is now an important part of the Oerlikon group Manmade Fibers

More information

CENTRIFUGAL CASTING MACHINES FOR THE FOUNDRY INDUSTRY

CENTRIFUGAL CASTING MACHINES FOR THE FOUNDRY INDUSTRY Tulsa Centrifugal Casting Machines LLC CENTRIFUGAL CASTING MACHINES FOR THE FOUNDRY INDUSTRY HORIZONTAL MACHINES PIT MOUNTED VERTICAL PORTABLE VERTICAL MACHINES ANCILLARY EQUIPMENT CONTACT US Tulsa Centrifugal

More information

RESEARCH PROJECT. High Pressure Die Casting Defects and Simulation Process by Computer Added Engineering (CAE)

RESEARCH PROJECT. High Pressure Die Casting Defects and Simulation Process by Computer Added Engineering (CAE) RESEARCH PROJECT High Pressure Die Casting Defects and Simulation Process by Computer Added Engineering (CAE) ME8109 CASTING AND SOLIDIFICATION OF MATERIALS Presented by: Irshad Ali (Student # 500482510)

More information

2.3 Adequate space and access shall be provided for all fan locations for maintenance and operations.

2.3 Adequate space and access shall be provided for all fan locations for maintenance and operations. HVAC FANS GENERAL INFORMATION 1.1 This section applies to centrifugal and axial fans. DESIGN REQUIREMENTS 2.1 The Consultant shall include such considerations as duct leakage (expect 5 percent), temperature

More information

STUDY OF PROCESS PARAMETERS OF GRAVITY DIE CASTING DEFECTS

STUDY OF PROCESS PARAMETERS OF GRAVITY DIE CASTING DEFECTS International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 2, March-April 2016, pp. 208 211, Article ID: IJMET_07_02_023 Available online at http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=7&itype=2

More information

A large number of metal components in designs we use every day are made by casting. The reasons for this include:

A large number of metal components in designs we use every day are made by casting. The reasons for this include: 1 Lecture 2. Basics of Metal-Casting 2.1. Casting methods Metal casting process begins by creating a mold, which is the reverse shape of the part we need. The mold is made from a refractory material, for

More information

Design of Cast Parts Avoid sharp corners, angles & fillets They act as stress raisers Select fillet radii to reduce stress concentrations and ensure p

Design of Cast Parts Avoid sharp corners, angles & fillets They act as stress raisers Select fillet radii to reduce stress concentrations and ensure p Metal Casting Design, Materials, Economics Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 12 Design of Cast Parts Avoid sharp corners, angles & fillets

More information

4. GRINDING MACHINE. 4.1 Introduction. 4.2 Types of grinding machines Rough grinding machines Precision grinding machines

4. GRINDING MACHINE. 4.1 Introduction. 4.2 Types of grinding machines Rough grinding machines Precision grinding machines 4.1 Introduction 4. GRINDING MACHINE Grinding is a metal cutting operation like any other process of machining removing metal in comparatively smaller volume. The cutting tool used is an abrasive wheel

More information

Lecture 33 continuous casting of steel. Keywords: continuous casting, tundish metallurgy, secondary cooling, defects in cast product

Lecture 33 continuous casting of steel. Keywords: continuous casting, tundish metallurgy, secondary cooling, defects in cast product Contents Introduction How casting is done continuously Tundish Mold secondary cooling Heat transfer in continuous casting Product and casting defect Lecture 33 continuous casting of steel Keywords: continuous

More information

CENTRIFUGAL PUMP OVERVIEW Presented by Matt Prosoli Of Pumps Plus Inc.

CENTRIFUGAL PUMP OVERVIEW Presented by Matt Prosoli Of Pumps Plus Inc. CENTRIFUGAL PUMP OVERVIEW Presented by Matt Prosoli Of Pumps Plus Inc. 1 Centrifugal Pump- Definition Centrifugal Pump can be defined as a mechanical device used to transfer liquid of various types. As

More information

Use of simulation tools in the practical development of a method for manufacture of Cast Iron Camshafts

Use of simulation tools in the practical development of a method for manufacture of Cast Iron Camshafts Use of simulation tools in the practical development of a method for manufacture of Cast Iron Camshafts M.R. Jolly, H.S.H. Lo, M. Turan, and J. Campbell IRC in Materials University of Birmingham, Birmingham,

More information

Defect formation in cast iron

Defect formation in cast iron Defect formation in cast iron School of Engineering Jönköping University Sweden Tammerfors, Finland, November 8, 2012 Introduction Casting Mould cavity Melting process Pouring Solidification Mould removal

More information

The Low-pressure Casting Technology of aluminum alloy motor

The Low-pressure Casting Technology of aluminum alloy motor 3rd International Conference on Material, Mechanical and Manufacturing Engineering (IC3ME 2015) The Low-pressure Casting Technology of aluminum alloy motor Guoding Yuan a,hai Gu b,jianhua Sun c,and Zhufeng

More information

Creating Casting Patterns Utilizing 3D CAD Data, Z-Corp 510 3D Printer and xlaform Resin Infiltration

Creating Casting Patterns Utilizing 3D CAD Data, Z-Corp 510 3D Printer and xlaform Resin Infiltration Creating Casting Patterns Utilizing 3D CAD Data, Z-Corp 510 3D Printer and xlaform Resin Infiltration New technologies combine to create casting patterns quickly and less expensively. Author: Harry Jansen

More information

Module - 2 Advanced Metal Casting Processes Lecture - 6 Ceramic Shell Investment Casting Process

Module - 2 Advanced Metal Casting Processes Lecture - 6 Ceramic Shell Investment Casting Process Advanced Manufacturing Processes Prof. Dr. Apurbba Kumar Sharma Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 2 Advanced Metal Casting Processes Lecture

More information

Production of ductile iron castings without feeders

Production of ductile iron castings without feeders Production of ductile iron castings without feeders Possibilities of producing ductile iron castings in green sand mould without feeders by means of "ingate" feeding and control of the graphite precipitation

More information

Foundry Instruction Sets

Foundry Instruction Sets Foundry Instruction Sets MCAM. Bell Casting Basic Training Set Introduction to sand casting: experiments with three different patterns (bell, anvil and anchor) MCLA. Foundry Building-up Training Set 1

More information

Installation Instruction

Installation Instruction Installation Instruction Caution Iron wire is prohibited to be used as conductive wire for this series of turbine generator units. Only aluminum wire or copper wire can be suitable. If the cable range

More information

Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling Channels for Block Laminated Molds

Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling Channels for Block Laminated Molds International Journal of Engineering and Advanced Technology (IJEAT ISSN: 2249 8958 Volume-4 Issue-5 June 2015 Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling

More information

Integration of manufacturing process simulation in to the process chain

Integration of manufacturing process simulation in to the process chain Integration of manufacturing process simulation in to the process chain Closing the gap between CAE supported design and manufacturing process simulation Achim Egner-Walter, Götz Hartmann, Marc Kothen

More information

Relevance of Modern Optimization Methods in Turbo Machinery Applications

Relevance of Modern Optimization Methods in Turbo Machinery Applications Relevance of Modern Optimization Methods in Turbo Machinery Applications - From Analytical Models via Three Dimensional Multidisciplinary Approaches to the Optimization of a Wind Turbine - Prof. Dr. Ing.

More information

DEVELOPMENT OF A METHOD FOR THE PRODUCTION OF ALUMINUM METAL FOAMS

DEVELOPMENT OF A METHOD FOR THE PRODUCTION OF ALUMINUM METAL FOAMS International Journal Metallurgical & Materials Science and Engineering (IJMMSE) ISSN(P): 2278-2516; ISSN(E): 2278-2524 Vol. 4, Issue 1, Feb 2014, 9-14 TJPRC Pvt. Ltd. DEVELOPMENT OF A METHOD FOR THE PRODUCTION

More information

ASSESSMENT OF CASTING FILLING BY MODELING SURFACE ENTRAINMENT EVENTS USING CFD

ASSESSMENT OF CASTING FILLING BY MODELING SURFACE ENTRAINMENT EVENTS USING CFD ASSESSMENT OF CASTING FILLING BY MODELING SURFACE ENTRAINMENT EVENTS USING CFD C Reilly, M.R Jolly, N.R Green, JC Gebelin The School of Engineering, The University of Birmingham, UK Keywords: Casting,

More information

MIT 2.810 Manufacturing Processes and Systems. Homework 6 Solutions. Casting. October 15, 2015. Figure 1: Casting defects

MIT 2.810 Manufacturing Processes and Systems. Homework 6 Solutions. Casting. October 15, 2015. Figure 1: Casting defects MIT 2.810 Manufacturing Processes and Systems Casting October 15, 2015 Problem 1. Casting defects. (a) Figure 1 shows various defects and discontinuities in cast products. Review each one and offer solutions

More information

Metal Powder Technology

Metal Powder Technology Metal Powder Technology Vacuum Induction Melting and Inert Gas Atomization Ceramic-Free Metal Powder Production Inert Gas Recycling 2 METAL POWDER TECHNOLOGY Metal powder technology is one of the most

More information

Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing

Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing J. Mater. Sci. Technol., Vol.24 No.1, 2008 65 Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing Chang-Seog Kang, Jae-Ik Cho, Chang-Yeol Jeong, Se-Weon Choi and Young-Chan

More information

Indo - German Winter Academy 06 Digha IIT KANPUR

Indo - German Winter Academy 06 Digha IIT KANPUR Indo - German Winter Academy 06 Digha IIT KANPUR Crystal Growth Simulations Shubham Gupta Electrical Engg. Mentor: Mr. Santhanu Jana Contents Crystal Growth: Need to Study. Various Growth Methods. Czochralski(Cz)

More information

Lecture 16. Furnace: Type and classification

Lecture 16. Furnace: Type and classification Lecture 16 Furnace: Type and classification Content of lecture What is a furnace? What are the components of a furnace? Furnaces and their applications in high temperature industries Issues in Furnace

More information

Finite Element Analysis of Semi-Solid Die-Casting Technology of Magnesium Alloy Hook Based on AnyCasting

Finite Element Analysis of Semi-Solid Die-Casting Technology of Magnesium Alloy Hook Based on AnyCasting Finite Element Analysis of Semi-Solid Die-Casting Technology of Magnesium Alloy Hook Based on AnyCasting Hanwu Liu Dep. of Mechanical and Electrical Engineering, North China Institute of Science and Technology

More information

Applications TVCd TVCs TCE-B TCE-A TMF TGEN TCF TSF-B

Applications TVCd TVCs TCE-B TCE-A TMF TGEN TCF TSF-B C A T A L O G U E 1 Company Profile TOPCAST is a company specialised in casting machines design and manufacturing. Competence developed in the investment casting field, thermal processes, induction heating

More information

Introduction to Metallography

Introduction to Metallography Introduction to Metallography Metallography has been described as both a science and an art. Traditionally, metallography has been the study of the microscopic structure of metals and alloys using optical

More information

Metal Casting processes

Metal Casting processes Metal Casting processes 3.1 Introduction of casting process: Casting process is one of the earliest metal shaping techniques. A metal casting may be defined as a metal object produced by pouring molten

More information

UNIT 20: Output Criteria: Solidification Time

UNIT 20: Output Criteria: Solidification Time UNIT 20: Output Criteria: Solidification Time Solidification Time shows the time, in minutes, for each part of the casting to become COMPLETELY solid, i.e., to cool to the Solidus Point. Viewing a plot

More information

Continuous melting and pouring of an aluminum oxide based melt with cold crucible

Continuous melting and pouring of an aluminum oxide based melt with cold crucible Continuous melting and pouring of an aluminum oxide based melt with cold crucible B Nacke, V Kichigin, V Geza, I Poznyak To cite this version: B Nacke, V Kichigin, V Geza, I Poznyak. Continuous melting

More information

Plastic Injection Molding

Plastic Injection Molding Training Objective After watching this video and reviewing the printed material, the student/trainee will understand the principles and physical operations of the plastic injection molding process. An

More information

Effect of Ultrasonic Treatment on the Microstructures and Mechanical Properties of Die Casting Aluminum Alloys

Effect of Ultrasonic Treatment on the Microstructures and Mechanical Properties of Die Casting Aluminum Alloys Proceedings of the 12th International Conference on Aluminium Alloys, September 5-9, 2010, Yokohama, Japan 2010 2010 The Japan Institute of Light Metals pp. 1735-1739 1735 Effect of Ultrasonic Treatment

More information

SUMMARY OF THE PACKED REFRACTORY RANGE For Full Specification see Technical Application Sheet

SUMMARY OF THE PACKED REFRACTORY RANGE For Full Specification see Technical Application Sheet SALPACK PRODUCTS MORCOAT 70 REF:MCT70A MORCEM 2 REF:MCM2A MCM3A MORCEM 900 REF:MCM900D MORRAM 8301 REF:MCM8301A SUMMARY OF THE PACKED REFRACTORY RANGE For Full Specification see Technical Application Sheet

More information

THE POSSIBILITIES OF RUNNER PLACEMENTS FOR CASTINGS PRODUCED BY SPIN CASTING INTO SILICON RUBBER MOULDS. Matej BEZNÁK, Martin BAJČIČÁK, Roland ŠUBA

THE POSSIBILITIES OF RUNNER PLACEMENTS FOR CASTINGS PRODUCED BY SPIN CASTING INTO SILICON RUBBER MOULDS. Matej BEZNÁK, Martin BAJČIČÁK, Roland ŠUBA THE POSSIBILITIES OF RUNNER PLACEMENTS FOR CASTINGS PRODUCED BY SPIN CASTING INTO SILICON RUBBER MOULDS Matej BEZNÁK, Martin BAJČIČÁK, Roland ŠUBA Authors: Matej Beznák, Assoc. Prof. PhD., Martin Bajčičák,

More information

METAL CASTING (FOUNDRY) BASICS & APPLICATIONS BY PROF. T. V. RAMANA RAO

METAL CASTING (FOUNDRY) BASICS & APPLICATIONS BY PROF. T. V. RAMANA RAO METAL CASTING (FOUNDRY) BASICS & APPLICATIONS BY PROF. T. V. RAMANA RAO 1 TOPICS FOR DISCUSSION 1. METAL CASTING PROCESS 2. COMPARISON WITH OTHER MANUFACTURING PROCESSES -ADVANTAGES AND LIMITATIONS 3.

More information

Hot tearing of Thin-walled Al-Mg Alloy in die-casting

Hot tearing of Thin-walled Al-Mg Alloy in die-casting Proceedings of the 12th International Conference on Aluminium Alloys, September 5-9, 2010, Yokohama, Japan 2010 @2010 The Japan Institute of Light Metals pp. 1811-1816 1811 Hot tearing of Thin-walled Al-Mg

More information

TILT POUR TRIALS AND ANALYSIS. Matrix Metals Keokuk Facility (Keokuk Steel Castings) Keokuk, Iowa 52632

TILT POUR TRIALS AND ANALYSIS. Matrix Metals Keokuk Facility (Keokuk Steel Castings) Keokuk, Iowa 52632 TILT POUR TRIALS AND ANALYSIS Bob Bryant 1, Kent D. Carlson 2, Shouzhu Ou 2, Christoph Beckermann 2 1 Matrix Metals Keokuk Facility (Keokuk Steel Castings) Keokuk, Iowa 52632 2 Department of Mechanical

More information

Injection molding equipment

Injection molding equipment Injection Molding Process Injection molding equipment Classification of injection molding machines 1. The injection molding machine processing ability style clamping force(kn) theoretical injection volume(cm3)

More information

Die Casting. high performance steels for Die casting

Die Casting. high performance steels for Die casting Die Casting high performance steels for Die casting YOUR AREAS OF APPLICATION FOR HIGH PRESSURE DIE CASTING Areas of application Die casting is a manufacturing process for producing aluminium, zinc, magnesium

More information

Sand Casting of Metals

Sand Casting of Metals Sand Casting of Metals Elizabeth Merten Department of Materials Science & Engineering University of Washington Seattle, WA 98195 emerten@u.washington.edu Copyright Edmonds Community College 2012 This material

More information

Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen

Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen Tagung des Arbeitskreises Thermophysik, 4. 5.3.2010 Karlsruhe, Deutschland E. Kaschnitz Österreichisches Gießerei-Institut

More information

DIRECT METAL PRINTERS. Metal Additive Manufacturing with the ProX DMP Series

DIRECT METAL PRINTERS. Metal Additive Manufacturing with the ProX DMP Series DIRECT METAL PRINTERS Metal Additive Manufacturing with the ProX DMP Series Go Further with Direct Metal Printing UNLOCK YOUR PRODUCT S POTENTIAL With complete design freedom, direct metal 3D printed parts

More information

Ablation of Hybrid Metal Matrix Composites

Ablation of Hybrid Metal Matrix Composites Paper 11-057.pdf, Page 1 of 7 Copyright 2011 American Foundry Society Ablation of Hybrid Metal Matrix Composites D. Weiss Eck Industries, Manitowoc, WI J. Grassi Alotech LLC Ltd., Brooklyn, OH B. Schultz,

More information

Introduction of Die Casting Process

Introduction of Die Casting Process Introduction of Die Casting Process Editor: Sanjian What is Die Casting Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity, which

More information

Physics 131: Test/Exam Problems: Rotations

Physics 131: Test/Exam Problems: Rotations Physics 131: Test/Exam Problems: Rotations 1) A uniform one-meter bar has a mass of 10 kg. One end of the bar is hinged to a building, and the other end is suspended by a cable that makes an angle of 45

More information

Numerical Simulation of Spheroidal Graphite Iron Casting for Shrinkage Analysis- A Case Study

Numerical Simulation of Spheroidal Graphite Iron Casting for Shrinkage Analysis- A Case Study Numerical Simulation of Spheroidal Graphite Iron Casting for Shrinkage Analysis- A Case Study Amol S. Karape PG Student, Department of Mechanical engineering Walchand College of Engineering Sangli, India

More information

Large Structures CFD Simulations For Water & Wastewater Treatment Plants. P. Fonseca, N. Marques, J. Azevedo, V. Rodrigues, M.

Large Structures CFD Simulations For Water & Wastewater Treatment Plants. P. Fonseca, N. Marques, J. Azevedo, V. Rodrigues, M. Large Structures CFD Simulations For Water & Wastewater Treatment Plants P. Fonseca, N. Marques, J. Azevedo, V. Rodrigues, M. Toïgo Outline 1. Introduction 2. Problem Overview 3. CFD modelling Strategy

More information

VALIDATION OF FOUNDRY PROCESS FOR ALUMINUM PARTS WITH FLOW3D SOFTWARE

VALIDATION OF FOUNDRY PROCESS FOR ALUMINUM PARTS WITH FLOW3D SOFTWARE LMPC 2011 VALIDATION OF FOUNDRY PROCESS FOR ALUMINUM PARTS WITH FLOW3D SOFTWARE Ngadia Taha Niane 1 and Jean-Pierre Michalet 2 1 PSA Peugeot Citroën; 18, rue des Fauvelles, 92250 La Garenne Colombes, FRANCE

More information

Fundamentals of Metal Casting

Fundamentals of Metal Casting Chapter 10 Fundamentals of Metal Casting QUALITATIVE PROBLEMS 10.15 Describe the stages involved in the contraction of metals during casting. The stages involved in the contraction of metals during casting

More information

df dt df dt df ds df ds

df dt df dt df ds df ds Principles of Fluid Mechanics Fluid: Fluid is a substance that deforms or flows continuously under the action of a shear stress (force per unit area). In fluid mechanics the term fluid can refer to any

More information

Welding of Plastics. Amit Mukund Joshi. (B.E Mechanical, A.M.I.Prod.E)

Welding of Plastics. Amit Mukund Joshi. (B.E Mechanical, A.M.I.Prod.E) Welding of Plastics Amit Mukund Joshi (B.E Mechanical, A.M.I.Prod.E) Introduction Mechanical fasteners, adhesives, and welding processes can all be employed to form joints between engineering plastics.

More information

Pushing the limits. Turbine simulation for next-generation turbochargers

Pushing the limits. Turbine simulation for next-generation turbochargers Pushing the limits Turbine simulation for next-generation turbochargers KWOK-KAI SO, BENT PHILLIPSEN, MAGNUS FISCHER Computational fluid dynamics (CFD) has matured and is now an indispensable tool for

More information

DESIGN OF TUNDISH FOR VACUUM OVER-PRESSURE INDUCTION MELTING DEVICE

DESIGN OF TUNDISH FOR VACUUM OVER-PRESSURE INDUCTION MELTING DEVICE DESIGN OF TUNDISH FOR VACUUM OVER-PRESSURE INDUCTION MELTING DEVICE Zbyněk HUDZIECZEK a), Vladislav KURKA a), Petra BĚDROŇOVÁ a), Jaroslav PINDOR a), Jiří CIENCIALA b) a) MATERIÁLOVÝ A METALURGICKÝ VÝZKUM

More information

Analysis of Casting Defects in Foundry by Computerised Simulations (CAE) - A New Approach along with Some Industrial Case Studies

Analysis of Casting Defects in Foundry by Computerised Simulations (CAE) - A New Approach along with Some Industrial Case Studies Analysis of Casting Defects in Foundry by Computerised Simulations (CAE) - A New Approach along with Some Industrial Case Studies Tapan Roy Asst. General Manager - Methods, Texmaco Rail & Engg. Ltd., Steel

More information

INTERNATIONAL JOURNAL OF APPLIED ENGINEERING RESEARCH, DINDIGUL Volume 1, No 4, 2011

INTERNATIONAL JOURNAL OF APPLIED ENGINEERING RESEARCH, DINDIGUL Volume 1, No 4, 2011 Solidification behavior and detection of Hotspots in Aluminium Alloy castings: Computer Aided Analysis and experimental validation Rabindra Behera 1, Kayal.S 1, Sutradhar.G 2 1 Research Scholar, Department

More information

MODELING OF AN AEROSPACE SAND CASTING PROCESS. A Thesis: submitted to the Faculty. of the WORCESTER POLYTECHNIC INSTITUTE

MODELING OF AN AEROSPACE SAND CASTING PROCESS. A Thesis: submitted to the Faculty. of the WORCESTER POLYTECHNIC INSTITUTE MODELING OF AN AEROSPACE SAND CASTING PROCESS A Thesis: submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE in partial fulfillment of the requirements for the Degree of Master of Science In

More information

Experimental Observation and Numerical Prediction of Induction Heating in a Graphite Test Article

Experimental Observation and Numerical Prediction of Induction Heating in a Graphite Test Article Excerpt from the Proceedings of the COMSOL Conference 2009 Boston Experimental Observation and Numerical Prediction of Induction Heating in a Graphite Test Article Todd A. Jankowski* 1, Debra P. Johnson

More information