Numerical Analysis to Investigate the Effect of Solidification Parameters on the Pull-In Effect of Continuous Casting

Fegade, Ritesh S.; Tated, Rajendrakumar G.; Nehete, R. S.

doi:10.1007/978-981-19-6032-1_25

Cited by 3 publications

(2 citation statements)

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“…At the initial stage of casting, these oxides must be Technologies and Processes in Applied Mechanics and Materials Research removed from the meniscus by a strong gas flow through the graphite ring. An oil or mold slag can be added to this part to avoid surface defects [19].…”

Section: Fig 5 the Aluminum Billet Hangs Up In The Mold During The Di...mentioning

confidence: 99%

The Start-Up Phase of Aluminum Billet Production Using Direct Chill Casting

Rajagukguk,

Suyitno,

Saptoadi

et al. 2024

AMM

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Direct chill (DC) casting has been considered as one of the promising casting methods that can be used to produce aluminum alloys billet. The process is conducted by pouring aluminum metal into a water-cooled mold. The billet shell begins to form when molten aluminum contact directly with the mold (this is also known as primary cooling). Afterward, the starting block is pulled downwards at a specified casting speed to achieve desired aluminum billet. The start-up phase during the DC casting process is considered a crucial step since it may determine the formation of defects in the casting products. This research aims to investigate the casting defects on the aluminum alloy that were formed during the start-up process of DC casting. The results show that the billet failed to form following the downward movement of starting block. Meanwhile, the billet tended to stick to the mold wall due to several factors, such as too low a pouring temperature, a less-round mold shape, the poor quality of the hot top and graphite ring, and the water that entered the mold during the casting process. It also noted several markers of the casting defects that occurred during the DC casting process such as liquation or bleeding, cold folding, billet stuck in the mold, butt structure, and rough billet surface.

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Section: Fig 5 the Aluminum Billet Hangs Up In The Mold During The Di...mentioning

confidence: 99%

The Start-Up Phase of Aluminum Billet Production Using Direct Chill Casting

Rajagukguk,

Suyitno,

Saptoadi

et al. 2024

AMM

View full text Add to dashboard Cite

show abstract

“…The production of high quality ingots and billets of large enough size required for further application is the main hurdle to cope up with the increasing demand [2]. The direct chill casting is the most widely used manufacturing process for the manufacture of large sized ingots and billets of Al, Cu, Mn, Zn alloys [3][4][5][6][7][8]. For the production of various end products used in a variety of applications, the ingots and billets produced by the direct chill casting process are rolled, forged and extruded [5].…”

Section: Introductionmentioning

confidence: 99%

Numerical investigation of pull in control of rectangular AA1050 rolling ingot through the design of convex mould during direct chill casting process

Fegade,

Tated,

Nehete

2024

Eng. Res. Express

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The pull in effect / concavity on the lateral faces of the ingot is formed during solidification of the ingot due to the thermal stresses induced in the ingot. A part of rolling ingots with pull in effect are cut by conventional cutting process which affects the recovery and increases wastage and cost of production. In the present work, an elemental death and birth technique was used to develop a numerical model to study mechanical and thermal behavior during solidification of AA1050 rolling ingot. The results of the model are validated with results of Williams model available in the literature. Furthermore, different mould designs provided with convexity on lateral surfaces with convexity radius of 16 mm to 26 mm were numerically analyzed. A series of numerical simulations were conducted with varying mould convexity with increment value of one. The results revealed that, providing convexity to the mould is an effective method to control the pull in effect during direct chill casting process. The convexity radius of 26 mm is enough to completely eliminate the pull in radius of 23.34 mm for the rectangular AA1050 ingot.

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