Elimination of Shrinkage in Ductile Iron Castings Using Computer Simulation of Casting and Solidification

被引:0
|
作者
Futas, Peter [1 ]
Pribulova, Alena [1 ]
Sabik, Vladimir [1 ]
Petrik, Jozef [1 ]
Blasko, Peter [1 ]
Brzezinski, Marcin [2 ]
机构
[1] Tech Univ Kosice, Fac Mat Met & Recycling, Letna 9, Kosice 04200, Slovakia
[2] AGH Univ Krakow, Fac Foundry Engn, Al Mickiewicza 30, PL-30059 Krakow, Poland
关键词
computer simulation; casting; foundry defects; shrinkage; gating system; feeder; VOLUME;
D O I
10.3390/pr12030506
中图分类号
TQ [化学工业];
学科分类号
0817 ;
摘要
The production of high-quality castings without foundry defects at minimal production costs is a constant priority for foundries. Innovation and optimization of production processes are key to achieving this goal. Computer simulation of foundry processes offers a modern alternative to expensive and time-consuming experiments in real foundries and provides a reliable representation and analysis of casting and solidification processes. A detailed analysis of the casting and solidification simulation results allows the prediction of various risks that can cause defects in cast castings, thereby reducing their quality and, last but not least, the cost of their production. This paper deals with the analysis of a computer simulation of the casting of a brake disc in a Slovak foundry. This brake disc has had shrinkages and micro shrinkages that reduce the internal quality of the casting. These defects occurred in the ribs in the upper part of the casting under the feeders. A computer simulation of the casting and solidification of this casting was made according to the real conditions. It turned out that the designed gating system with a system of feeders was not sufficient to eliminate the emerging defects. A new layout for the feeders was proposed, which ultimately eliminated the occurrence of defects based on the results of the computer simulation. The input parameters were set to be as close as possible to the actual needs of the foundry. Moreover, 3D models of the assemblies were designed in SolidWorks Premium 2015 x64 Edition CAD software, and the filling and solidification simulations were performed using the NovaFlow & Solid CV 4.6r42 simulation program.
引用
收藏
页数:15
相关论文
共 50 条
  • [41] An innovative method for estimating the fatigue strength of ductile iron castings in the presence of solidification defects
    Borsato, T.
    Ferro, P.
    Carollo, C.
    Berto, F.
    METALLURGIA ITALIANA, 2019, 111 (7-8): : 21 - 30
  • [42] COMPUTER SIMULATION OF THE SOLIDIFICATION IN BILLET CONTINUOUS CASTING.
    Junze, Jin
    Xianshu, Zheng
    Keren, Guo
    Han, Zhong
    Zheng, Wang
    Zhongmin, Zhang
    Kang T'ieh/Iron and Steel (Peking), 1985, 20 (05): : 19 - 27
  • [43] MOULD TAPER OPTIMIZATION FOR CONTINUOUS CASTING STEELS BY SOLIDIFICATION SHRINKAGE SIMULATION
    Cai, Shaowu
    Wang, Tongmin
    Li, Jun
    Xu, Jingjing
    Du, Yanyan
    Luo, Dawei
    Li, Tingju
    Jin, Junze
    MODELING OF CASTING, WELDING, AND ADVANCED SOLIDIFICATION PROCESSES - XII, 2009, : 173 - 179
  • [44] Computer Simulation and Experimental Investigation of Solidification Casting Process
    Suraya, S.
    Sulaiman, S.
    Ariffin, M. K. A.
    Sayuti, M.
    COMPOSITE SCIENCE AND TECHNOLOGY, PTS 1 AND 2, 2011, 471-472 : 601 - 605
  • [45] Examination and Elimination of Defects in Cone Casting Made of Ductile Cast Iron
    Guzik, E.
    Lagowski, M.
    Nowak-Dudek, A.
    Niedzielski, B.
    ARCHIVES OF FOUNDRY ENGINEERING, 2013, 13 (04) : 43 - 48
  • [47] The influence of carbon and silicon content in ductile iron on shrinkage creation for castings with different wall thickness
    Conev, Martin
    Vasková, Iveta
    Hrubovčáková, Martina
    Eperješi, Štefan
    Pribulová, Alena
    Manufacturing Technology, 2017, 17 (02): : 163 - 168
  • [48] Study on thermal simulation of solidification in heavy section ductile iron
    Li, ZH
    Li, YX
    Geng, HY
    Chen, JJ
    Zhou, CY
    Chen, JF
    JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY, 2003, 19 : 122 - 124
  • [49] Investigation on effect of carbon equivalent and inoculation on the solidification and shrinkage tendency of ductile cast iron using thermal analysis
    Sangame, Bahubali Babanrao
    Reddy, Y. Prasannatha
    MULTIDISCIPLINE MODELING IN MATERIALS AND STRUCTURES, 2024, 20 (01) : 1 - 17
  • [50] Solidification pattern of 4.5%Si ductile iron in metal mould versus sand mould castings
    Stan, Iuliana
    Anca, Denisa-Elena
    Riposan, Iulian
    Stan, Stelian
    JOURNAL OF THERMAL ANALYSIS AND CALORIMETRY, 2023, 148 (05) : 1805 - 1817