Study on the heat transfer at the casting-mould interface in resin-bonded sand mould casting of Mg-Gd-Y-Zr alloy
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The heat transfer at the casting-mould interface in resin-bonded sand mould casting of Mg-Gd-Y-Zr alloy was investigated, in which plate-shaped castings with different thicknesses were produced and the temperature variation in the casting and sand mould was recorded. The heat flux and the interfacial heat transfer coefficient (IHTC) were determined by a verified inverse heat conduction model. The results showed that the peak value of the heat flux was about 34~68 kW/m2 and it approximately increased with the decrease of the casting thickness. The averaged heat flux in the solidification process increased from 25.4 kW/m2 to 42.4 kW/m2 when the casting thickness decreased from 35 mm to 10 mm. The IHTC increases rapidly after the liquid metal was poured into the mould, and then decreases for a while, followed by a gentle increase. The averaged IHTC in the solidification process is about 105~183 W/m2K.Keywords:
Sand casting
Investment casting
Combining SLA prototyping with conventional investment casting technology,the two kinds of quick precision casting technologies were investigated.The characteristics of these quick precision casting technologies were discussed,which had important guiding roles for similar production activity and furthered the application of rapid prototyping technology.
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Investment casting method can fabricate the impeller slots with non-uniform thickness and distorted surface. The process of investment casting can be simulated by employing ProCAST software. The mesh of the casting was introduced in the article. The influence about the initial temperature of shell on the defects of the casting and the pouring temperature and the pouring speed on the effective stress of the casting was studied in this article. When the initial temperature of shell was 400°C,there was no defect in the casting. The pouring temperature of the casting, will produce a very strong influence on the effective stress. When the pouring temperature in this article was 800°C, the maximum effective stress of the casting was 108MPa.
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Investment casting
Shrinkage
Sand casting
Foundry
Structural material
Machinability
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The use of rapid prototyping technologies to create new industrial products, with particular importance isthe cost and speed of production, is a unique opportunity to use cost-effective methods for the production ofparts by investment casting. At the stage of pilot production, which is characterized by frequent changes indesign, the problem of the rapid production of cast components becomes crucial. This is mainly due to thecomplexity and the complexity of manufacturing foundry equipment. In turn, the research and development ofrapid prototyping technologies have allowed a new level of optimization and the introduction of newtechnologies in the investment casting. The aim of this work is to identify opportunities and evaluate accuracy ofthe size of the casting during investment casting using rapid prototyping technology. The work was conductedwith the use of cross-cutting design in CAM / CAD / CAE systems. The study size and precision parameters ofthe casting was conducted in co-ordinate measuring machine. The work has been verified the adequacy of thevirtual simulation of the process of forming a casting in the casting simulation ProCAST, in comparison withthose obtained castings. The study showed that the use of rapid prototyping technologies with investment castingcan significantly reduce the time for making castings, reduce production costs and improve the accuracy of thesize of the casting.
Investment casting
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This paper investigates the possibility of a large casting by investment precision casting methods using urea As the actual investment precision casting method is used, this data will be adopted to another actual investment precision casting method, including the lost wax method for the application and operation of this experiment
Conclusions are as follows' the large casting produced by the Investment precision casting method has a clean surface that has no fishtail casting defects, and also the machining time is shoter than that of existing lost wax methods For the higher surface precision of casting, urea is necessary for the investment precision casting method In the investment casting method without the urea, ceramic shell thickness cannot be controlled The ceramic shell of existing investment casting is irregular compared to that of investment precision casting because the surface of the ceramic shell is transferred to the casting which produces a more desirable surface and reduce machining time to the precision products Through the study, it will achieve improvement of the investment precision casting method
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Investment casting
Selective laser sintering
Sand casting
Near net shape
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Investment casting
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Abstract This article is aimed at an aluminum alloy special-shaped part, which has a hollow connection inside, and there are multiple cross-sections that are constantly changing, and it is difficult to design the casting process. In response to this difficulty, combined with the existing sand casting, metal casting and investment casting production lines of the factory, the casting process plan is designed and optimized now. With the help of the numerical simulation software Anycasting, through the simulation analysis of the casting process, the problem that the castings are prone to defects in the thin wall and the bottom plate is solved. The conclusions obtained from the simulation analysis were applied to the actual production process, and qualified castings were produced.
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Some simulation examples of investment casting utilizing Procast software were introduced. The results show that the software can predict the casting defects formed during filling and solidification processes, thus can aid technologists to optimize casting process and guide the practical production of investment casting. The simulation method has the reference for the design of other casting processes as well.
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