Prediction of distortions and pattern allowances during sand casting of a steel bracket

Galles, D.; Beckermann, C.

doi:10.1080/13640461.2016.1262984

Cited by 8 publications

(3 citation statements)

References 12 publications

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“…The control of deformation is usually performed with iteration of trial-and-error process, which is time-consuming. [3] Accurate prediction of deformation is essential to reduce waste caused by experimental iteration of trial-and-error. Numerical approaches such as finite element method has been introduced into the prediction of deformation with the development of computational technology, which leads to paradigm shift in casting design, from physical, experimental and empirical to digital and virtual.…”

Section: Introductionmentioning

confidence: 99%

Semi-solid plasticity and deformation control of superalloy investment casting

Ding

Wang²,

Guan³

et al. 2023

Preprint

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The deformation in superalloy investment casting under thermal-mechanical coupled stress is causing huge waste of materials and energy. Mechanical models of both alloy and shell are essential to predict the deformation of castings accurately. The elastoplastic behavior of superalloy in semi-solid zone is critical to the deformation during solidification. In this paper, the deformation of ring-to-ring castings with Ni-based superalloy K4169 is researched. To obtain the thermal-mechanical behavior of K4169 from solid region to semi-solid zone, physical simulated uniaxial compression is performed. Yield stress and plastic modulus from the measurement are imported into the database for numerical simulation. Different thermal-mechanical models of both alloy and shell are compared. With elastoplastic model for alloy, considering the deformability of shell with elastic model, the accuracy of prediction is within CT4 level, with a maximum error of 0.39mm. The deformation of reaches the minimum when the initial temperature of alloy and shell are 1500℃ and 900℃. The research on semi-solid performance of alloy and thermal-mechanical models can provide theoretical guidance for deformation prediction. The method of this research is promising in dimensional control of castings, and can be transported to dimensional control problems upon solidification process with different kinds of materials and castings.

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Section: Introductionmentioning

confidence: 99%

Semi-solid plasticity and deformation control of superalloy investment casting

Ding

Wang²,

Guan³

et al. 2023

Preprint

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“…The transition processes are accompanied by thermal expansion because at higher temperatures more open crystal structures are favoured. Expansion properties of different types of foundry sands and the effect of various additives and bonding agents on the thermal expansion of moulds and cores are common topics of foundry research [3][4][5][6][7][8][9][10][11]. Some reports also mention the partial investigation of specific size ranges of silica sands.…”

Section: Introductionmentioning

confidence: 99%

The origin of thermal expansion differences in various size fractions of silica sand

Svidró

Diószegi

Svidró

2020

International Journal of Cast Metals Research

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In this study, thermophysical properties of a commonly used silica sand were investigated and their relation to its granulometric and chemical composition was studied. Thermal expansion and differential scanning calorimetry tests were performed on individual fractions of the silica sand together with X-ray fluorescence measurements to determine their constituents. It was found that the various size fractions of silica sand exhibit different levels of thermal expansion based on the differences in SiO 2 content. The expansion behaviour of two additional silica samples and a recycled olivine sand was also investigated in relation to its grain size to justify the findings.

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“…Distortions create inefficiencies throughout the casting process that can adversely impact lead times and generate considerable waste. 19 Control on casting dimensions improves foundry productivity significantly. 20 This research work is carried out by conducting a set of experimentation to study the effect of various process parameters at selected levels on dimensional accuracy of casting.…”

Section: Introductionmentioning

confidence: 99%

Optimization of process parameters to improve dimensional accuracy of investment casting using Taguchi approach

Bansode¹,

Phalle²,

Mantha³

2019

Advances in Mechanical Engineering

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In this study, Taguchi method is used to investigate the effect of critical process parameters of investment casting on dimensional variations of thin walled, complex geometrical stainless steel component. A set of experiments have been conducted to calculate shrinkages which is a measure of dimensional variation. The process parameters considered here are number of ceramic coats, pouring time, pouring temperature, and casting cooling rate. The signal-to-noise ratio and analysis of variance are used to study the influence of these parameters on shrinkage. Optimized condition for reduced shrinkage deviation can be obtained by selecting lower number of ceramic coats, faster and laminar metal pouring, lower superheated metal temperature, and faster cooling rate. Analysis of variance reports that the number of ceramic coats is the most significant parameter with more than 80% contribution whereas other parameters are insignificant. Investigation results also indicate that constraint dimension (width) has 25%-27% higher dimensional variability than non-constraint dimensions (height) for the selected component.

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Prediction of distortions and pattern allowances during sand casting of a steel bracket

Cited by 8 publications

References 12 publications

Semi-solid plasticity and deformation control of superalloy investment casting

Semi-solid plasticity and deformation control of superalloy investment casting

The origin of thermal expansion differences in various size fractions of silica sand

Optimization of process parameters to improve dimensional accuracy of investment casting using Taguchi approach

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