Progress in numerical simulation of casting process

Chen, Zhengyang; Li, Yueyang; Zhao, Fangyu; Li, Shi; Zhang, Ji

doi:10.1177/00202940221102656

Cited by 14 publications

(5 citation statements)

References 67 publications

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“…Control equations of filling simulation of casting process mainly consists of mass conservation, Navier-Stokes equation, energy conservation, volume of fluid. 27…”

Section: Condition Of Simulation and Experimentsmentioning

confidence: 99%

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Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Jin

2023

Advances in Mechanical Engineering

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Bottom-up gated filling system was performed to produce worm wheel through a sand casting of zinc alloy. It was a symmetrical design in which two worm wheels were cast at once, the worm wheel was erected in the direction of gravity and had a gating system in which molten zinc alloy were poured from below. The recovery rate of the designed mold cavity was 60%. Casting analysis was performed to check that the worm wheel was sequentially filled without turbulent flow as the molten zinc alloy passed through the gate. Though the speed of the molten zinc alloy initially poured was unstable, it became stabilized while maintaining a constant speed due to the continuous inflow. The results of directional solidification were confirmed. An integrated mold cavity pattern was fabricated by 3D printer, and sand mold were manufactured accordingly. A sound worm wheel without defects could be fabricated through sand casting.

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“…Control equations of filling simulation of casting process mainly consists of mass conservation, Navier-Stokes equation, energy conservation, volume of fluid. 27…”

Section: Condition Of Simulation and Experimentsmentioning

confidence: 99%

“…Control equations of filling simulation of casting process mainly consists of mass conservation, Navier-Stokes equation, energy conservation, volume of fluid. 27 Zamak 3 alloy was used in casting experiment. The main alloy composition of zamak 3 was 4.0 wt.% aluminum and 0.8 wt.%.…”

Section: Condition Of Simulation and Experimentsmentioning

confidence: 99%

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Jin

2023

Advances in Mechanical Engineering

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“…This technology has several advantages: (1) it directly affects the solidification and crystallization mechanism of the internal structure of the slab, reduces the superheat of molten steel, and shortens the depth of the liquid phase cavity; (2) it reduces columnar crystals and increases equiaxed crystals; (3) it reduces central segregation, porosity, and shrinkage; (4) this method requires less investment and energy consumption, low operational cost, convenient equipment maintenance and repair, and provides apparent improvements [73,74].…”

Section: Technology Of Feeding Steel Strip Into a Mouldmentioning

confidence: 99%

Recent advances in inclusions and central segregation control technology in tyre cord steel and saw wire steel

Chen

Wang

Sun

et al. 2022

Ironmaking & Steelmaking

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Tyre cord wires and steel saw wires represent typical precision pearlitic steel wire rods. Reducing the rate of wire breaking is one of the most concerning problems in metallurgy. This paper surveys the technical progress in the control of inclusions and central segregation in tyre cord steel wires and saw wire steel in the last 20 years, including the control of the [Al]s content in steel, selection of better refractories, deletion of the VD process, developing of new kinds of refining slag system, optimize the structure of tundish, control of Ti-containing inclusions, feeding steel trip into a mould, electromagnetic stirring technology, soft reduction technology at the solidification end of continuous casting slab, and the control of billet size. Finally, the unresolved issues that should be studied in the next 10 years have been formulated.

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“…In casting simulations, it is possible to predict the flow of molten metal, temperature distribution, the correctness of the parameters and design of the gating and feeding system, the solidification time of the casting, and possible casting defects. The main benefits of using casting simulation are time and cost savings, increased safety, process optimization, higher efficiency, and better product quality [44][45][46].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Sand Casting of Stainless Steel Pump Impeller

Jurković,

Schauperl,

Šolić

et al. 2024

Metals

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This paper investigates the casting defects of a stainless steel pump impeller manufactured through the sand casting process. The material characterization of austenitic steel AISI 316L was initially carried out, which examined the chemical composition of the casting and its microstructure. The next step was to determine the cause of the casting defects using numerical simulations. The numerical simulations were performed using ProCAST software (Version 18.0). Initial results of the filling and solidification simulations were conducted using the parameters employed in the actual casting process, revealing casting defects in corresponding locations. The casting process was subsequently modified to achieve improved results. This involved reconstructing the gating system, redesigning the riser, and incorporating a cylindrical chiller. The results show that the modified casting process significantly reduces the occurrence of defects in the final product. The study provides useful insights into the analysis and modification of the casting process for stainless steel pump impellers produced through sand casting. The results can help improve the quality of such products and reduce production costs associated with casting defects.

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Progress in numerical simulation of casting process

Cited by 14 publications

References 67 publications

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Recent advances in inclusions and central segregation control technology in tyre cord steel and saw wire steel

Numerical Simulation of Sand Casting of Stainless Steel Pump Impeller

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