Download or read book Predict the Gating System Design on the Tensile Strengthen in the Sand Casting Using Computational Fluid Dynamic written by and published by . This book was released on 2012 with total page 104 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Automated system for designing gating system of sand casting written by Dr. Chandan Deep Singh and published by BookRix. This book was released on 2018-01-15 with total page 97 pages. Available in PDF, EPUB and Kindle. Book excerpt: Designing in sand casting is a critical activity for manufacturing. Further, activities like cavity design, cavity layout and design of gating system are essential in design. Design of gating system in sand casting is dependent upon a various parameters. Gating system design requires lot of manual input and a number of iterations to finalize the design. This requires a good knowledge of casting process, making this activity completely dependent on the user. In present day industry, lot of CAD/CAM tools are applied for design, development and manufacturing. However, need of sand casting expert throughout design and manufacturing makes it a quite lengthy process. Gating system design being one of the major activities also takes much time. Therefore, it would be quite beneficial to develop a system for automated generation of gating system. Proposed system takes CAD file of the die casting part as input and uses sand casting process, machine and alloy knowledge to determine different parameters for the gating system. Designs of the components of the gating system like runner, gate and overflow have been attempted. A feature library has been proposed as a part of this work which together with parametric design of the gating system generates CAD model of the components of the gating system. The system would go a long way in bridging the gap between designing and manufacturing of die-casting.

Download or read book Proceedings of the 2nd International Conference on Experimental and Computational Mechanics in Engineering written by Akhyar and published by Springer Nature. This book was released on 2021-05-31 with total page 525 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book gathers a selection of peer-reviewed papers presented at the 2nd International Conference on Experimental and Computational Mechanics in Engineering (ICECME 2020), held as a virtual conference and organized by Universitas Syiah Kuala, Banda Aceh, Indonesia, on 13–14 October 2020. The contributions, prepared by international scientists and engineers, cover the latest advances in computational mechanics, metallurgy and material science, energy systems, manufacturing processing systems, industrial and system engineering, biomechanics, artificial intelligence, micro/nano-engineering, micro-electro-mechanical system, machine learning, mechatronics, and engineering design. The book is intended for academics, including graduate students and researchers, as well as industrial practitioners working in the areas of experimental and computational mechanics.

Download or read book Development of a Model to Predict Sand Rate for a Given Angle head Electrical Resistance Probe Output Using Computational Fluid Dynamics CFD written by Satish Kumar Pabba and published by . This book was released on 2008 with total page 290 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Investigation Into Non Conventional Mold Designs Using 3D Sand Printing in Castings written by Santosh Reddy Sama and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: In recent years, Additive Manufacturing (AM) technologies are fueling a paradigm shift in the advanced manufacturing landscape across all industrial sectors. The metal casting industry is also taking advantage of the wide variety of rapid manufacturing solutions offered by AM processes. The metal casting industry supports about 90% of total manufactured goods and is expected to reach a market size of about 40 billion USD by 2025. Sand casting is the most widely used metal casting process and utilizes expendable molds that demand expensive tooling, high lead time and limited flexibility in their fabrication. In addition, limitations in process control and feasible gating and feeding systems, traditional sand casting experiences higher scrap rates. AM offers an alternative mold fabrication technology known as 3D Sand-Printing (3DSP) process that enables direct digital manufacturing of complex expendable sand molds and cores without any tooling requirements. Ever-growing interest in this indirect metal AM process is attributed to its ability to rapidly produce cores and molds for complex metal castings that are otherwise impossible to manufacture using conventional techniques. Knowledge-based design rules for this process are currently very limited and are progressively realized in an ad-hoc basis to produce economic low-volume castings. Despite the wealth of knowledge in metal AM, no work to date has been reported to take advantage of design complexity offered by 3DSP in developing optimal gating and feeding designs to mitigate casting defects. This thesis provides the first known investigation into the application of design freedom offered by 3DSP to transform and monitor sand casting performance. Non-conventional design rules for gating and risering (also known as rigging) systems are developed to reduce surface turbulence, oxide films, air entrapment, bubble damage and several other casting defects, and improved metallic yield. Several case studies are presented to illustrate the improved casting performance through systematically reengineering elements of the rigging system viz. pouring basin, sprue, runners and risers. Their efficacy is validated through computational simulations and experimental procedures. Of the various components of gating system, innovative sprue design provides the highest opportunity to improve casting quality. Numerical models for novel parabolic and conical-helix sprue profiles can be developed through constrained optimization algorithm based on principles of casting hydrodynamics to reduce surface turbulence. Computational flow simulations, computed tomography scanning, microstructure and mechanical characterization experiments are performed to validate that incorporation of 3D Sand-Printing featured mathematically optimized gating systems (particularly conical-helix sprues) to significantly improve the performance of sand castings.Finally, existing foundry technologies have very limited capabilities to monitor real-time flow conditions of liquid metal during mold filling. Two approaches for novel non-intrusive real-time mold fill monitoring by embedding inexpensive miniature Internet of Things (IoT) sensors into 3d sand-printed molds are proposed. These sensor technologies are based on the electrical properties of molten metals, the former measuring the magnetic flux generated by the conductive liquid and the latter measuring the interference of electric fields by modifying dielectric near the sensor. Experiments are conducted to evaluate the efficacy of both these concepts. Results from experiments validate that IoT sensors can be embedded into 3DSP molds to successfully monitor flow fields that can be used to benchmark simulation results and optimize gating systems.

Download or read book Design of Casting and Gating Systems written by Ján Majerník and published by . This book was released on 2021 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Computer Aided Design of Gating Systems of Sand Castings written by Chengming Wang and published by . This book was released on 1985 with total page 292 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Rapid Tooling Guidelines For Sand Casting written by Wanlong Wang and published by Springer. This book was released on 2010-11-05 with total page 164 pages. Available in PDF, EPUB and Kindle. Book excerpt: Rapid Tooling Guidelines for Sand Casting describes the guidelines for the sand casting industry in using rapid tooling processes. Topics in the seven chapters include sand casting processes, tool design and construction, fast freeform fabrication processes, rapid tooling processes, sand casting dimension control, rapid tooling evaluation methods and decision making processes. Twelve case studies will also be examined in the book.

Download or read book Investigation Into Novel Runner Extension Designs for Sand Casting Utilizing 3D Sand Printing written by Ryan Stebbins and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Casting is one of the oldest manufacturing methods, dating to 5000 B.C. Its influence can still be seen today, accounting for a $110 billion impact on the US economy in 2019. Sand casting, is the most popular casting process due to its ability to produce relatively complex parts with almost any alloy at comparatively low costs, as well as manufacture both large components and small precision castings. Despite its prominence, casting has design limitations such as required draft angles and parting lines due to required tooling and patterns, which has led to the exploration of new manufacturing methods, such as additive manufacturing (AM). AM allows for increased part complexity, reduced material usage, part consolidation, usage of lattices, and decreased lead time between design and production. The rise of this novel technology is reflected in the large influx in publications and patents involving AM within in the past couple decades. However, its limitations in part size, cost, and available alloys prevent it from fully replacing casting. The merger of both sand casting and AM binder jetting into a hybrid manufacturing method is called 3D sand printing (3DSP), and it offers the benefits of both methods. With the advent of 3DSP, more complex geometries and castings are possible, allowing for the redesign and optimization of gating and rigging systems for defect reduction and improvements in casting quality. Despite research having already explored redesigning gating components like pouring basins, sprues, and runners using more complex mold geometries realizable through 3DSP, no research has considered the use of 3DSP for runner extensions. This thesis investigates various runner extension designs for the purpose of defect reduction. Out of the six different runner extension designs, three required 3DSP due to complexity. All designs were evaluated using simulation and experimental validation to ascertain their impact on casting quality. Designs were derived from literature review of gating system concepts. Simulations were completed using Flow-3D Cast v5 CFD software, comparing the resulting entrained air, tracer particles, and void particles present in the casting cavity. Results indicated difference between designs but required additional experimental comparisons to conclude runner extension impact. Designs were tested on manually poured Al319 cast plates, using a hybrid mold making method of both green sand and 3DSP extension molds. A total of eighteen plates were cast, three per design, all of which were scanned with computed tomography (CT) to determine the defect volume fraction present in the final castings. Three-point bending bars were machined from cast plates and tested to compare extension designs impact on mechanical properties. Statistical analysis of both mechanical performance and defect volume fraction showed no differences between runner extension designs. The results obtained in this thesis aid for the further optimization of gating systems and helping foundries reach zero defect casting.

Download or read book An Object Oriented Approach to Design the Gating System for a Casting written by Satyanarayana Golla and published by . This book was released on 1994 with total page 306 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Gating Design and Mold Filling in the Lost Foam Casting Process written by Mickey Dean Lawrence and published by . This book was released on 1995 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: "Gating and mold filling of castings in the lost foam casting process have been studied to determine the importance of processing parameters and how these parameters can be used to control mold filling. The research in paper 1 describes the statistically significant effects of processing parameters and gating system design for an industry-type hat-shaped pattern on mold filling characteristics such as fill time, horizontal velocities, and vertical velocities. The permeability of the refractory coating is the most important variable. The metallostatic pressure head and the pouring temperature also affected the mold filling characteristics to a smaller degree. A maximum velocity (about 1 in./s.) cannot be exceeded if a sound castings is to be produced. Paper 2 describes how processing parameters might be used to predict and control the mold filling in the lost foam casting process. The research involved four steps. Step 1, which used a pattern for a tube holder for a heat exchanger (the pendant pattern), explored ways to force the pattern to fill faster than the runner and to skew the progressing metal front towards the gates in order to force any foam decomposition products into the gating system. Although some improvements were made, this was only accomplished when a straight plate pattern was substituted for the curved pendant pattern. Step 2 used the information from step 1 and previous work to produce a model which predicted the position of the molten metal front throughout the filling process of a pump housing pattern. It was found that intersections involving sharp direction changes from vertical to horizontal flow have a sizable effect on the velocity of the molten metal front as the pattern fills. The slope of the line, when actual time was plotted versus the expected time, also differed because the actual pattern had a higher density than those used to produce the model. Step 3 explored in more detail the effect that sharp direction changes have on mold filling characteristics in simple plate patterns. The effect of the intersection on the flow of the molten aluminum was confirmed. The change in velocity was measured as a jump in the elapsed time when plotted against the predicted time. Step 4 included the effect of the intersection on the predicted metal front progression in an industry-type pipe pattern casting. The predictions were not confirmed, suggests that the effect of intersections is more complex expected. More research on the effect of direction changes must be performed in order to make a model that accurately predicts mold filling in the lost foam process"--Abstract, leaves iv-v

Download or read book Metals Abstracts written by and published by . This book was released on 1996 with total page 1650 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book The Basic Principles of Fluid Dynamics Applied to Running Systems of Castings written by T. L. Sutton and published by . This book was released on 2007 with total page 104 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Castings Practice written by John Campbell and published by Elsevier. This book was released on 2004-04-16 with total page 218 pages. Available in PDF, EPUB and Kindle. Book excerpt: Each chapter of Professor Cambell's new book Castings Practice will take a look at one of his 10 rules. It is to be expected that the Rules wil one day be taken as an outline or blueprint for an international specification on the methods for making reliable castings.John Cambell has over two decades of experience in the casting industry and is the author of over 40 technical papers and patents. He has become well-known in the foundry industry as the originator of the Cosworth casting process, which is becoming accepted throughout the world as a new production process for the casting of cylinder heads and blocks. He is now Federal Mogul Professor of Casting Technology at the University of Birmingham. * Must-follow rules of castings, from one of the world's leading experts* Companion volume to the renowned book 'Castings' * Accessible and direct, provides essential information for students of metallurgy and foundry professionals alike

Download or read book Complete Casting Handbook Metal Casting Processes Metallurgy Techniques and Design written by John Campbell and published by Butterworth-Heinemann. This book was released on 2017-11-13 with total page 1220 pages. Available in PDF, EPUB and Kindle. Book excerpt: Complete Casting Handbook is the result of a long-awaited update, consolidation and expansion of expert John Campbell s market-leading casting books into one essential resource for metallurgists and foundry professionals who design, specify or manufacture metal castings. The first single-volume guide to cover modern principles and processes in such breadth and depth whilst retaining a clear, practical focus, it includes: A logical, two-part structure, breaking the contents down into casting metallurgy and casting manufacture Established, must-have information, such as Campbell s 10 Rules for successful casting manufacture New chapters on filling system design, melting, molding, and controlled solidification techniques, plus extended coverage of a new approach to casting metallurgy Providing in-depth casting knowledge and process know-how, from the noteworthy career of an industry-leading authority, Complete Casting Handbook delivers the expert advice needed to help you make successful and profitable castings. Long-awaited update, consolidation and expansion of expert John Campbell s market-leading casting books into one essential handbook Separated into two parts, casting metallurgy and casting manufacture, with extended coverage of casting alloys and new chapters on filling system design, melting, moulding and controlled solidification techniques to compliment the renowned Campbell 10 Rules Delivers the expert advice that engineers need to make successful and profitable casting decisions "

Download or read book Cast Iron Technology written by Roy Elliott and published by Butterworth-Heinemann. This book was released on 1988-04-18 with total page 253 pages. Available in PDF, EPUB and Kindle. Book excerpt: Cast Iron Technology presents a critical review of the nature of cast irons. It discusses the types of cast iron and the general purpose of cast irons. It also presents the history of the iron founding industry. Some of the topics covered in the book are the description of liquid metal state; preparation of liquid metal; process of melting; description of cupola melting and electric melting methods; control of composition of liquid metal during preparation; description of primary cast iron solidification structures; and thermal analysis of metals to determine its quality. Solidification science and the fundamentals of heat treatment are also discussed. An in-depth analysis of the hot quenching techniques is provided. The graphitization potential of liquid iron is well presented. A chapter is devoted to microstructural features of cast iron. The book can provide useful information to iron smiths, welders, students, and researchers.

Download or read book Handbook of Manufacturing Engineering and Technology written by Andrew Y. C. Nee and published by Springer. This book was released on 2014-10-31 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Springer Reference Work Handbook of Manufacturing Engineering and Technology provides overviews and in-depth and authoritative analyses on the basic and cutting-edge manufacturing technologies and sciences across a broad spectrum of areas. These topics are commonly encountered in industries as well as in academia. Manufacturing engineering curricula across universities are now essential topics covered in major universities worldwide.