Article
Metallurgy & Metallurgical Engineering
Tong Wang, Lei Wang, Zelin Zhang, Huan Zhang, Xuhui Xia, Jianxin Zhou
Summary: With the development of high-speed computer technology, casting CAE and casting CAD have effectively improved the design efficiency and accuracy of the casting process. This paper presents a framework for the integration of casting CAD, process optimization, and casting CAE, allowing for the rapid and convenient design of the casting process. The traditional passive mode of artificial experience has been replaced by an active mode of intelligent system optimization. The key technologies for establishing this integrated system are analyzed in detail. A successful integrated system for the optimization of gating and riser processes in steel casting has been developed, providing new ideas and key technology for intelligent process design of steel castings.
INTERNATIONAL JOURNAL OF METALCASTING
(2023)
Article
Thermodynamics
Chul Kyu Jin
Summary: A bottom-up gated filling system was used to produce a symmetrical design of worm wheels through sand casting of zinc alloy. The designed mold cavity had a 60% recovery rate and a gating system for pouring the molten zinc alloy from below. Casting analysis confirmed sequential filling of the worm wheel without turbulent flow. Directional solidification and the manufacture of sand molds using a 3D printed integrated mold cavity pattern resulted in defect-free worm wheels.
ADVANCES IN MECHANICAL ENGINEERING
(2023)
Article
Chemistry, Physical
Bo He, Yiyu Lei, Mengqi Jiang, Fei Wang
Summary: A route utilizing a multi-objective EA and single-objective optimization algorithm was developed to assist in designing gating and riser systems, leading to a dramatic decrease in design time cost.
Article
Materials Science, Multidisciplinary
Zhiqiang Duan, Weipeng Chen, Xiaolong Pei, Hua Hou, Yuhong Zhao
Summary: In this study, a novel machine learning-based design strategy is proposed for the gating system of large and complex thin-walled castings. The gating system of castings was estimated using a multi-input multi-output neural network model, which incorporated visual, textual, and numerical multimodal features. Simulation software was utilized for comparison and verification, resulting in a smooth filling and sequential solidification.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Metallurgy & Metallurgical Engineering
Shuyang Ren, Feng Wang, Zheng Liu, Pingli Mao, Jingying Sun
Summary: A gating system for semi-solid rheocasting of aluminum alloy was designed using numerical simulations, and the effects of process parameters on filling performance were studied. The optimal die casting parameters were selected through orthogonal test analysis, and the quality of the produced semi-solid aluminum alloy components was confirmed by observing the microstructure characteristics.
INTERNATIONAL JOURNAL OF METALCASTING
(2022)
Article
Engineering, Marine
Yui Okubo, Taiga Mitsuyuki
Summary: This paper proposes a method to automatically create a realistic production plan by modeling and process simulation, considering the complexity of the target shipbuilding project, and quantitatively evaluating the bottleneck of the shipyard and worker reallocation plan.
JOURNAL OF MARINE SCIENCE AND ENGINEERING
(2022)
Article
Robotics
Tonghuan Ding, Bo Li, Hu Liu, Yan Peng, Yi Yang
Summary: This letter discusses the development of a planar multi-closed-loop hyper-redundant manipulator. By using extendable tape springs and inner tube rods, the proposed manipulator achieves a large workspace with a small footprint. The manipulator can be configured in various ways by controlling the drive components. The kinematic model is established and a configuration planning approach based on optimal stiffness is proposed. Simulations and experiments validate the design and method.
IEEE ROBOTICS AND AUTOMATION LETTERS
(2022)
Article
Materials Science, Multidisciplinary
Xiaoping Zhu, Chunlei Zhu, Baosen Lin, Zidong Wang
Summary: The effect of the cast process procedure and pouring systems on several typical metallurgical defects for TiAl case casting was studied. Gravity casting showed better melt-filling stability and synchronization compared to centrifugal casting. By designing a suitable inner-gate structure and increasing the bottom cross runners, the misrun defects in the thin-walled outer ring and the negative effect of overheated zone in the thick-walled flange could be effectively resolved. The crack induced by stress concentration in the transition zone poses significant challenges for TiAl case casting and can be resolved through structural design and process optimization.
Article
Metallurgy & Metallurgical Engineering
Yi Chen Kao, Ming-Hsiu Ho, Han Wei Tseng, Cheng-Fu Huang, Sheng-Chan Lee, Chien-Wei Chan, Yiin-Kuen Fuh
Summary: This study numerically analyzed the potential defects in investment casting and compared different gating designs. The best casting scheme was chosen for experimental verification.
INTERNATIONAL JOURNAL OF METALCASTING
(2022)
Article
Engineering, Mechanical
Hussein Alrobei, Rizwan Ahmed Malik, Abid Hussain, Meshal Alzaid, Lamia Ben Farhat, Irfan Anjum Badruddin
Summary: This study systematically examined the impacts of gating design and riser system on the structure-property relationship of high manganese steel specimens produced by CO2 sand molding process. Castings designed using the SolidCast simulation method showed fewer defects and improved mechanical properties compared to castings designed manually.
JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY
(2022)
Article
Chemistry, Physical
Andrzej Kielbus, Robert Jarosz
Summary: The research successfully improved the existing gating system for engine body casting using the new EV31A magnesium alloy, by conducting casting process simulations and experimental validation. The design modifications effectively addressed potential problems and factors that reduce the casting quality, enabling the implementation of the new alloy in industrial production.
Article
Green & Sustainable Science & Technology
Yoonshin Kwak, Brian Deal, Grant Mosey
Summary: Resilient design in contemporary landscape architecture requires interdisciplinary efforts to address uncertainty, with gaps existing between academic research and physical practice. This study proposes a framework that integrates analytic research and design creation, and tests it through a pilot study using a sociohydrological model to support more resilient landscape design creation. The framework and pilot study highlight the importance of bridging the gap between science and practice for the creation of resilient communities.
Article
Metallurgy & Metallurgical Engineering
Amir Moradi, Mehdi Divandari
Summary: Although the filling stage is short in the metal casting process, it plays a significant role in the casting quality. The design and dimensions of the filling system affect the filling rate, metal velocity, and surface turbulence, which are crucial for the reliability of the casting. This study investigates the effect of ingate size, shape, and geometry on the flow characteristics of molten metal in order to find an appropriate filling system for a hollow cylinder. Three different bottom-gating filling systems with different ingate shapes are proposed and compared using CFD simulation software. The results show that the fan ingate shape introduces less turbulent flow compared to the rectangular ingate shape, reducing air entrainment. Additionally, the ring ingate shape, with sufficient total ingate cross section and utilizing uphill metal flow, can reduce metal velocity entering the cavity and eliminate air entrainment.
INTERNATIONAL JOURNAL OF METALCASTING
(2023)
Article
Materials Science, Multidisciplinary
Carlos E. S. Albuquerque, Paulo C. S. Silva, Estephanie N. D. Grassi, Carlos J. De Araujo, Joao M. P. Q. Delgado, Antonio G. B. Lima
Summary: This work optimizes the injection system used in a non-traditional investment casting process using virtual prototyping and casting numerical simulation. Advanced CAD techniques are used to design the casting system of a complex shape profile with high surface finish requirements. The ProCAST software is employed for numerical simulation and experimental parameters are used as input data. By optimizing the nozzle model and adding a compensation volume, the alloy recirculation and shrinkage porosity issues are successfully eliminated.
Article
Chemistry, Physical
Stefan Gaspar, Tomas Coranic, Jan Majernik, Jozef Husar, Lucia Knapcikova, Dominik Gojdan, Jan Pasko
Summary: This study analyzed the influence of design solutions of the inlet system on the properties of Al-Si castings through computer modeling and experimental verification. The height of the inlet notch is a key factor significantly influencing the properties and filling speed of the mold cavity. Additionally, there is a significant correlation between porosity and the mechanical properties of the castings.
