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Virtual Mold Technique in Thermal Stress Analysis during casting process

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Journal of Materials Science & Technology 2008年第3期24卷 359-363页

作者： Si-Young Kwak Jae-Wook Baek Jeong-Ho Nam Jeong-Kil Choi E-Design Center Korea Institute of Industrial Technology Department of Virtual Engineering Korea University of Science & Technology

It is important to analyse the casting product and the mold at the same time considering thermal contraction of the casting and thermal expansion of the mold. The analysis considering contact of the casting and the mold induces the precise prediction of stress distribution and the defect such as hot tearing. But it is difficult to generate FEM mesh for the interface of the casting and the mold. Moreover the mesh for the mold domain spends lots of computational time and memory for the analysis due to a number of meshes. Consequently we proposed the virtual mold technique which only uses mesh of the casting part for thermal stress analysis in casting process. The spring bar element in virtual mold technique is used to consider the contact of the casting and the mold. In general, a volume of the mold is much bigger than that of casting part, so the proposed technique decreases the number of mesh and saves the computational memory and time greatly. In this study, the proposed technique was verified by the comparison with the traditional contact technique on a specimen. And the proposed technique gave satisfactory results.

关键词： casting process Thermal stress analysis Virtual mold

Development of 2D casting process CAD system based on PDF/image files

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China Foundry 2014年第5期11卷 440-446页

作者： Tang Hongtao Zhou Jianxin Wang Lin Liao Dunming Tao Qing School of Mechanical and Electronic Engineering Wuhan University of Technology State Key Laboratory of Materials processing and Die & Mould Technology Huazhong University of Science & Technology

A casting process CAD is put forward to design and draw casting process. The 2D casting process CAD, most of the current systems are developed based on one certain version of the AutoCAD system. However the application of these 2D casting process CAD systems in foundry enterprises are restricted because they have several deficiencies, such as being overly dependent on the AutoCAD system, and some part files based on PDF format can not be opened directly. To overcome these deficiencies, for the first time an innovative 2D casting process CAD system based on PDF and image format file has been proposed, which breaks through the traditional research and application notion of the 2D casting process CAD system based on AutoCAD. Several key technologies of this system such as coordinate transformation, CAD interactive drawing, file storage, PDF and image format files display, and image recognition technologies were described in detail. A practical 2D CAD casting process system named HZCAD2D(PDF) was developed, which is capable of designing and drawing the casting process on the part drawing based on the PDF format directly, without spending time on drawing the part produced by AutoCAD system. Finally, taking two actual castings as examples, the casting processes were drawn using this system, demonstrating that this system can significantly shorten the cycle of casting process designing.

关键词： 2D casting process CAD casting process PDF format development of 2D CAD storage of file

Integration of CAD/CAE System for casting process Design

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Tsinghua Science and Technology 2003年第1期8卷 117-120页

作者：周舰荆涛 Department of Mechanical Engineering Tsinghua University

Concurrent engineering is needed to modernize the foundry industry and to reduce the scrap from castings and thus increase the economic profit. This paper presents an integrated 3-D CAD/CAE system for a foundry using concurrent engineering which considers casting structure, casting type, and manufacturing properties in the CAD module to design the pouring system, the riser, the chill core and so on. A visualized solid model is developed for the casting component with the model design enhanced by CAE analysis. Heat transfer and fluid flow simulation are used to analyze the initial design. The whole product development process is analyzed using concurrent engineering methods. The application shows that the integrated system can improve the efficiency of the design and manufacturing process of die casting.

关键词： concurrent engineering computer aided design (CAD)/computer aided engineering (CAE) casting process

Numerical Simulation System for casting process in Concurrent Engineering

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Tsinghua Science and Technology 1999年第2期4卷 59-63页

作者：李永保柳百成邱伟 Department of Mechanical Engineering Tsinghua University Beijing 100084

According to the implementing principle and application background of the Concurrent Engineering (CE) project, studies on the integration of numerical simulation system for casting process with CE, simulation of turbulent phenomena in filling process of casting by Algebraic Stress Model (ASM), computation efficiency of filling process and quantitative prediction of shrinkage cavity and porosity under feeding condition of several risers are discussed. After the simulation of casting process of typical magnesium based alloy casting with complicated structure, remarkable success in assuring the quality is also presented.

关键词： casting process numerical simulation Concurrent Engineering Algebraic Stress Model

Magnesium Alloy Wheel Structure Design and Wheel casting process Performance Analysis

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材料科学与工程（中英文B版） 2022年第3期12卷 75-77页

作者： Xin Jiang Xinwei Lan Department of System Design Engineering Keio University3-14-1HiyoshiKohoku-kuYokohamaKanagawa 223-8522Japan Members Company 1-8-10Chuo CityHarumiTokyoJapan

Recently,as the automotive industry is increasingly demanding on energy saving and environmental protection,people are paying more attention to the lightweight design and comfort of *** is a very important part of wheel *** method includes centrifugal casting,sand casting,high pressure casting,low pressure casting and so *** this research,magnesium alloy wheel casting numerical simulation was carried *** of casting process was researched based on finite element theory,filling and solidification data at the end of the simulation were obtained for guidance of produce.

关键词： Magnesium alloy wheel casting process finite element method

Burning characteristics of high density foamed GAP/CL-20 propellants

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Defence Technology（防务技术） 2022年第10期18卷 1914-1921页

作者： Man-man Li Rui Hu Ming-hui Xu Qiong-lin Wang Wei-tao Yang Xi'an Modern Chemistry Research Institute Xi'an710065PR China School of Physics Xi'an Jiaotong UniversityXi'an710049PR China

The monolithic foamed propellants with high densities were prepared by casting and two-step foaming *** azide polymer(GAP)and isocyanate were used as the binder system and 2,4,6,8,10,12-hexanitro-2,4,6,8,10,12-hexaazaisowurtzitane(HNIW,CL-20)was employed as the energetic *** newly designed formulation containing 60%CL-20 produced a force constant of 1077 J/g and low flame temperature of 2817 *** foamed propellants with densities of 1.32 g/cm^(3)and 1.53 g/cm^(3)were fabricated by a confined foaming process and examined by closed bomb *** results revealed that porosity significantly affects burning performance.A size effect on combustion behaviors was observed for the foamed propellant with 5.56%porosity,and a double-hump progressive dynamic vivacity curve was *** last,the 30 mm gun test was carried out to demonstrate the interior ballistic performance,and the muzzle velocity increased by 120 m/s at the same maximum chamber pressure when monolithic propellant was added in the charge.

关键词： Monolithic foamed propellants Two-step foaming process casting process GAP/CL-20

Microstructure and mechanical properties of AZ91-Ca magnesium alloy cast by different processes

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China Foundry 2018年第4期15卷 263-269页

作者： xiao-yang chen yang zhang ya-lin lu xiao-ping li Key lab of advanced Materials Design and Additive Manufacturing of Jiangsu Province Jiangsu University of TechnologyChangzhou 213001 China

The microstructure and mechanical properties of magnesium(Mg) alloys are significantly influenced by the casting process. In this paper, a comparative study on microstructure and mechanical properties at ambient and elevated temperatures of AZ91-2 wt.% Ca(AZX912) Mg alloy samples prepared by gravity casting(GC), squeeze casting(SC) and rheo-squeeze casting(RSC), respectively, was carried out. The results show that α-Mg grains in SC and RSC samples are significantly refined compared to the GC sample. The average secondary dendritic arm spacing of AZX912 alloy samples decreases in the order of GC, SC and RSC. As testing temperature increases from 25 °C to 200 °C, strength of AZX912 alloy samples is reduced, while their elongation is increased continuously. Compared to GC and SC processes, RSC process can improve the mechanical properties of AZX912 alloy at both ambient and elevated temperatures. The enhancement of mechanical properties of RSC sample over GC and SC samples mainly results from grain refinement in the as-cast microstructure of AZX912 alloy.

关键词： magnesium alloys casting process microstructure mechanical properties

Grain refinement of commercial pure Al treated by Pulsed Magneto-Oscillation on the top surface of melt

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China Foundry 2015年第1期12卷 48-53页

作者： Dong Liang Zhu-yuan Liang Jie Sun Qi-jie Zhai Wang Gui David H.StJohn Shanghai Key Laboratory of Modern Metallurgy & Materials processing Shanghai University Centre for Advanced Materials processing and Manufacturing The University of Queensland

Commercial pure Al can be refined by Pulsed Magneto-Oscillation(PMO) treatment applied via a plate induction coil above the top surface of the melt. The proportion of the equiaxed zone area increases with decreasing Height to Diameter(H/D) ratios from 3.5 to1.8 and further to 1.0. Meanwhile, it increases and then decreases with increasing peak current for the three kinds of ingots with H/D ratios of 3.5, 1.8 and 1.0, respectively. However, when the H/D ratio decreases to 0.44, the area proportion of equiaxed zone can reach the maximum value with a lower peak current. FEA software simulation indicates that smaller H/D ratio results in larger current density, electromagnetic force and convection on the top surface of the melt, favoring nucleation and subsequent grain formation. Through evaluating Joule heating effect by PMO, it was found that the proper amount of Joule heating benefits grain refinement. Excessive Joule heating can reduce the size of the equiaxed zone and change the growth morphology of the grains.

关键词： grain refinement casting process nucleation and growth finite element(FE) simulation pulsed magneto-oscillation(PMO)

A review of additive manufacturing technology and its application to foundry in China

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China Foundry 2021年第4期18卷 249-264页

作者： Shi-yan Tang Li Yang Zi-tian Fan Wen-ming Jiang Xin-wang Liu State Key Laboratory of Materials processing and Die&Mould Technology School of Materials Science and EngineeringHuazhong University of Science and TechnologyWuhan 430074China

The application of additive manufacturing technology is one of the main approaches to achieving the rapid *** manufacturing technology can directly prepare casting molds(cores)with no need of patterns,and quickly cast complex *** combination of additive manufacturing and traditional casting technology can break the constraint of traditional casting technology,improve casting flexibility,and ameliorate the working ***,additive manufacturing promotes the realization of"free casting",greatly simplifying the processing procedures and shortening the manufacturing *** paper summarizes the basic principle of additive manufacturing technology and its development situation domestically and overseas,mainly focusing on the development status of several main additive manufacturing technologies applicable to the foundry field,including three-dimensional printing,selective laser sintering,stereolithography,layered extrusion forming,***,the future development trend of additive manufacturing technology in the foundry field is prospected.

关键词： additive manufacturing rapid prototyping 3D printing casting process rapid casting