Numerical and experimental approach to eliminate defects in al alloy pump- crank case processed through gravity die casting route

Aravind, S.; Ragupathi, P.; Vignesh, G.

doi:10.1016/j.matpr.2020.07.365

Cited by 12 publications

(8 citation statements)

References 23 publications

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“…Aluminium 7075 is selected for this particular study due to its comprehensive properties like low density, high strength, ductility, toughness and resistance to fatigue. 1,21 A pouring temperature of 963 K is considered to be optimal based on the various studies on casting aluminium alloys. 22 Out of all the available sands, Chromite sand is selected for the casting as it has advantages such as low silica percentage, high fusion temperature (2123 K), and high thermal conductivity.…”

Section: Methodsmentioning

confidence: 99%

Exploring Casting Defects of AA7075 Alloy in the Gravity Die Casting Simulation of an IC Engine Block

Aneesh

Pawan

Mohan

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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The present work aims to investigate the different casting defects that arose during the gravity die casting process of an IC engine block made of AA 7075 alloy and also highlights the feasible solutions to eradicate those defects. The minimization of the casting defects is a very crucial task in an IC engine block. Experimental studies which are generally performed to reduce the casting defects are proven to be strenuous, costly, and time-consuming. To counter this, a thermal simulation model is proposed in the present study to identify the effect of the pouring temperature, mould temperature, and the number of chillers on the various casting defects such as cold shuts, air entrapment, mould erosion, and microporosity. A detailed parametric study is conducted on the proposed model to evaluate the outcomes of important process variables on the resulting casting defects. The simulation results predict, at pouring temperature of 963 K, mould temperature of 293.15 K and with the use of 2 chillers defect-free IC engine blocks can be casted. The optimum result obtained by the proposed model is validated by conducting a confirmative test predicting an average error of 6.98%. The proposed model is effective enough in getting rid of the numerous casting defects which cannot be identified using the traditional methods; thus increasing productivity. This can be used as an economical time-saving substitute to the experimental methods during casting of various engine parts.

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Section: Methodsmentioning

confidence: 99%

Exploring Casting Defects of AA7075 Alloy in the Gravity Die Casting Simulation of an IC Engine Block

Aneesh

Pawan

Mohan

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…MAGMASOFT software is used for numerical investigation in order to detect certain defects such as issues in riser level, solidification, which leads to shrinkage and imperfections in the mould cavity, which helps to improvise the process of casting in aluminum based alloys by the method of gravity. The results concluded that changing design helps to improve the defects in the centrifugal pump crank case [7]. High-pressure die casting is investigated for AL-10 wt % Si alloy by using a scanning electron microscope, computed tomography (CT) and optical microscope (OM).…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Abdulhadi

2021

EEJET

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Die casting is forcing molten metal into a mould with high pressure. Die casting has two dies namely moving die and fixed die where the moving one will move over the fixed die. Die casting is majorly used for high-volume production. This paper focused on the physical phenomenon of die casting for two dies (moving die and fixed die) using two different alloy materials with variable material chemical compositions. The numerical analysis is carried out for the die casting process to determine the crack formation zone by temperature distribution and structural analysis by stress-strain relationship. The numerical analysis is carried out for both the dies. The fixed die is analyzed with an H13 tool steel material with two moving die materials as aluminum alloy (A356) and magnesium alloy (AZ91D). Both the dies (fixed and moving) were designed by using design software and meshing is carried out followed by analysis using the analysis software. The physical parameter for the dies is applied that is temperature distribution is carried out by applying a temperature of 850 °C and 650 °C over the fixed die for aluminum and magnesium alloy, respectively. Structural analysis is carried out for the moving die with a load of 1,000 N for both aluminum and magnesium alloys with 1000 number of iterations. The results from the numerical analysis are derived and analyzed for both temperature distribution and structural analysis. The crack formation zone is found out by means of temperature gradient and the stress-strain relationship is found out by means of structural analysis. From the results, it was concluded that the crack zone is obtained at 1.22E-10 °C/mm and 6.856E-14 °C/mm of thermal gradient and structural analysis in terms of maximum stress of 446.94 MPa and 448.52 MPa for aluminum and magnesium alloys, respectively.

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“…In contrast, cast aluminum alloy is more popular due to its low production cost, but the performance of an aluminum alloy produced by the casting process is not so desirable [11]. Squeeze casting technology, precisely combining the advantages of both casting and forging, has broad application prospects in terms of low cost, a short process and high-quality mass production, and is a key technology for the future replacement of steel with aluminum, using casting instead of forging to achieve high performance and lightweight manufacturing of large complex structural parts [12,13].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Validation of Squeeze Casting of AlSi9Mg Aluminum Alloy Component with a Large Size

et al. 2022

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The squeeze casting process for an AlSi9Mg aluminum alloy flywheel housing component was numerically simulated using the ProCAST software, and orthogonal simulation tests were designed according to the L16 (4) 5 orthogonal test table to investigate the alloy melt flow rule under four factors and four levels each of the pouring temperature, mold temperature, pressure holding time and specific pressure, as well as the distributions of the temperature fields, stress fields and defects. The results showed that the flywheel housing castings in all 16 test groups were fully filled, and the thinner regions solidified more quickly than the thicker regions. Hot spots were predicted at the mounting ports and the convex platform, which could be relieved by adding a local loading device. Due to the different constraints on the cylinder surface and the lower end surface, the solidification was inconsistent, the equivalent stress at the corner junction was larger, and the castings with longer pressure holding time and lower mold temperature had larger average equivalent stress. Shrinkage cavities were mainly predicted at mounting ports, the cylindrical convex platform, the peripheral overflow groove and the corner junctions, and there was also a small defect region at the edge of the upper end face in some test groups.

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Numerical and experimental approach to eliminate defects in al alloy pump- crank case processed through gravity die casting route

Cited by 12 publications

References 23 publications

Exploring Casting Defects of AA7075 Alloy in the Gravity Die Casting Simulation of an IC Engine Block

Exploring Casting Defects of AA7075 Alloy in the Gravity Die Casting Simulation of an IC Engine Block

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Numerical Simulation and Experimental Validation of Squeeze Casting of AlSi9Mg Aluminum Alloy Component with a Large Size

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