Optimization of residual stress in low-pressure casting of ZL205A alloys

Zhang, Zonghao; Liu, Jianhui; Chen, Jin‐Ming; Wen, Fulin; Jia, Runping; Ma, Qiang

doi:10.1016/j.jmapro.2023.05.040

Cited by 8 publications

(2 citation statements)

References 66 publications

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“…In order to achieve the design strategy of the nonlinear pressurization curve mentioned above, the filling behaviors of different ratios of cross-section area under different gating velocities should be analyzed. Recently, a large number of researches have been conducted to optimize CGC processes based on simulation and coupled experiments [13][14][15][16][17][18]. Moreover, machine learning-based design strategy has been proposed for the gating system design of CGC [19].…”

Section: Introductionmentioning

confidence: 99%

A novel nonlinear pressurization method for counter-gravity casting of cross-sectional mutation structures

Qiu,

Zhang,

Cao

et al. 2024

Preprint

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In order to ensure the filling integrity of complex counter-gravity casting and improve metallurgical quality, it is necessary to shorten the filling time while avoiding air entrainments. To address this contradiction, a novel nonlinear pressurization method was proposed in this study. Through systematically analyzing the relationship between critical filling speed and stable filling height, a criterion for iterative calculation of nonlinear pressurization speed was established, and an empirical expression between nonlinear pressurization speed and the filling height was obtained. Based on the empirical expression, a nonlinear pressurization curve can be designed according to the casting structures and initial pressurization speeds. The above nonlinear pressure curve design method was validated through water simulation. It was proved that the nonlinear pressure curve can shorten the filling time while avoiding air entrainments. It provides important processing control method for improving the low-pressure casting performance of complex castings.

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Section: Introductionmentioning

confidence: 99%

A novel nonlinear pressurization method for counter-gravity casting of cross-sectional mutation structures

Qiu,

Zhang,

Cao

et al. 2024

Preprint

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“…Due to the complex content of ZL205A material alloy elements, and with a wide crystallization range and various uncertainties in the casting process, various defects often occur, resulting in organizational performance that does not reach the service requirements [6,7]. Most researchers have carried out research on how to improve the strength of aluminum alloys [8,9]. However, the component has plane, hole, and other cutting structures, resulting in a direct impact on the service performance of the component in the application process [10,11].…”

Section: Introductionmentioning

confidence: 99%

Thermodynamic Analysis Based on the ZL205A Alloy Milling Force Model Study

Cui,

Shen,

Xin

et al. 2023

Lubricants

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The ZL205A aluminum alloy is mostly used in automobiles, aircraft, aerospace, and other mechanical components, but now, it focuses on the study of its casting performance, and there is still a lack of research on its cutting performance. In this paper, the milling ZL205A aluminum alloy was milled for testing and simulation analysis. The milling test showed that the impact of the axial cutting depth, radial cutting depth, feed, and cutting speed on the milling force was successively reduced. A thermodynamic analysis model is proposed to evaluate the cutting force and tool design in milling. The model considers the front angle and friction angle of the tool, in which the friction angle is adjusted by the friction coefficient, the variable is the cutting parameter, the constant is fitted through the milling experiment, and the effectiveness of the model is verified to predict the milling force. The pre-grinding test was carried out before the experiment, and the stability of the test was proved by observing the macroscopic shape of the chip and the wear of the cutting edge. The model comprehensively considers the tool angle and quickly calculates the minimum load on the milling cutter based on the optimal geometric parameters, which can be used to optimize the milling cutter structure and provide a theoretical basis for the preparation of ZL205A aluminum alloy mechanical components.

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