Numerical modeling and simulation of water cooling-controlled solidification for aluminum alloy investment casting

Zhang, Shouyin; Xu, Zhonghai; Wang, Zhitai

doi:10.1007/s00170-016-9808-5

Cited by 17 publications

(5 citation statements)

References 7 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…As can be seen, the actual average cooling time for an injection mold with conventional cooling channels was about 361.1 s. The standard deviation was about 12.7 s. The actual average cooling time for an injection mold with optimum CCCs was about 109.2 s. The standard deviation was about 6.8 s. However, the actual cooling time for an injection mold without cooling channels was about 952.1 s. It is clear that the reduction in cooling time of about 89% was obtained. As can be seen, the low-volume production of wax patterns can be fabricated swiftly and inexpensively for investment casting of metal components with simple geometries [ 39 , 40 ]. The cooling time can be shortened for an injection mold with optimum, but the cooling efficiency is limited to the thermal conductivity of the mold materials.…”

Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

View full text Add to dashboard Cite

Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.

show abstract

Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

View full text Add to dashboard Cite

show abstract

“…This means that the price–performance ratio of this SRM made by the optimal recipe is around 55. It should be noted that the SRM made with recipe 4 seems to be a promising method to manufacture wax patterns for manufacturing customized metal components through investment casting technology [ 54 , 55 , 56 , 57 ]. However, adding fillers into the SRM changes the material composition, which brings other problems, including wasted material recycling and environmental friendliness are also important research issues.…”

Section: Resultsmentioning

confidence: 99%

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Kuo

2021

Polymers

View full text Add to dashboard Cite

Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

show abstract

“…Once the reformer model is secured, the whole system is sink in a water bath at a temperature of between about 5 and 12 ° C for a period corresponding to about one production cycle. [6] Fig. 1…”

Section: Analysis Of Wax Pattern Blades Segment Manufacturing Cyclementioning

confidence: 99%

Archives of Foundry Engineering

Herman

Kubelkova

Vratny

2019

View full text Add to dashboard Cite

Precision casting is currently motivated by high demand especially for castings for the aerospace, automotive and gas turbine industries. High demands on precision of this parts pressure foundries to search for the new tools which can help them to improve the production. One of these tools is the numerical simulation of injection process, whereas such software especially for investment casting wax injection, process does not exist yet and for this case must be the existing software, for alloys or plastic, modified. This paper focuses on the use of numerical simulations to predict the behavior of injected models of gas turbine blades segments. The properties of wax mixtures, which were imported into the Cadmould simulation software as a material model, were found. The results of the simulations were verified using the results of 3D scanning measurements of wax models. As a supporting technology for verifying the results was used the Infrared Thermography. .

show abstract

Numerical modeling and simulation of water cooling-controlled solidification for aluminum alloy investment casting

Cited by 17 publications

References 7 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Archives of Foundry Engineering

Contact Info

Product

Resources

About