Quantitative Prediction of Air Entrainment Defects in Casting Filling Process

• Autorzy: Yin Yajun , Xie Yao , Song Yingchen , Shen Xu , Ji Xiaoyuan , Zhou Jianxin

Identyfikatory

DOI

10.24425/afe.2023.146686

• Języki publikacji: EN

Abstrakty

EN

Air entrainment defect is a common type of defect in the casting process, which will seriously affect the quality of the casting. Numerical simulation technology can predict the occurrence of casting defects according to the evolution law of liquid metal in the process of filling and solidification. The simulation of air entrainment process is a hot and difficult issue in the field of numerical simulation. The evolution law of air entrainment and the tracking of induced bubbles in the process of metal filling are still lacking. So is the quantitative prediction of trained gas. In this paper, based on the numerical simulation software of Inte CAST, this paper proposes an algorithm for air entrainment search and tracking, which is used to develop a quantitative prediction system for air entrainment. The feasibility of the system is verified through the simulation calculation of the typical test pieces of the air entrainment and the prediction of air entrainment defects of the casting in the process of filling is obtained through the simulation calculation of the actual casting, which can provide a certain guiding role for the optimization of the process in the production practice.

Słowa kluczowe

EN

casting; numerical simulation; air entrainment; filling process

PL

odlew; symulacja numeryczna; napowietrzanie; proces odlewania; wady

• Wydawca: Komisja Odlewnictwa Polskiej Akademii Nauk Oddział w Katowicach
• Czasopismo: Archives of Foundry Engineering
• Rocznik: 2023
• Tom: Vol. 23, iss. 4
• Strony: 117--126
• Opis fizyczny: Bibliogr. 14 poz., rys., tab., wykr.

Twórcy

autor

Yin Yajun

• Huazhong University of Science and Technology, China

autor

Xie Yao

• State Key Laboratory of Special Rare Metal Materials, China

autor

Song Yingchen

• Huazhong University of Science and Technology, China

autor

Shen Xu

• Huazhong University of Science and Technology, China

autor

Ji Xiaoyuan

• Huazhong University of Science and Technology, China

autor

Zhou Jianxin

• Huazhong University of Science and Technology, China

Bibliografia

• [1] Hu, L., Feng, Z.P., Feng, L., Duan, S.P. & Liang, S.P. (2016). Numerical simulation of porosity defects in casting filling process. DOI:10.16410/j.issn1000-8365.2016. 02.030. (in Chinese)
• [2] Bi, C. (2016). Study on numerical simulation of gas entrapment and external solidified crystals during mold filling of high pressure die casting process. Doctoral dissertation, Tsinghua University. (in Chinese).
• [3] Yu, M.Q., Xia, W., Cao, W.J. & Zhou, Z.Y. (2010). Numerical simulation of filling process and air entrapment condition of Al alloy die-casting. Hot Working Technology. 01, 36-39. DOI:10.14158/j.cnki.1001-3814.2010.01.039. (in Chinese).
• [4] Hernández-Ortega, Juan, J., Zamora, Rosendo, & Palacios, et al. (2007). Experimental and numerical study of air entrapment during the filling of a mould cavity in die casting. In 10th Esaform Conference on Material Forming, 18-20 April 2007 (1430-1435). Zaragoza, Spain.
• [5] Guerra, F.V., Archer, L., Hardin, R.A & Beckermann C. (2019). Measurement of air entrainment during pouring of an aluminum alloy. Shape Casting. 80, 31-40. https://doi.org/10.1007/s11663-020-01998-3.
• [6] Chen, Y.X., Chen, Z. & Liao, D.M. (2021). Prediction of air entrapment defect in casings based on gas phase tracking and bubble breaking criterion. Foundry. 70(07), 806-812.
• [7] Caboussat, A., Picasso, M. & Rappaz, J. (2005). Numerical simulation of free surface incompressible liquid flows surrounded by compressible gas. Journal of Computational Physics. 203(2), 626-649. https://doi.org/10.1016/ j.jcp.2004.09.009.
• [8] Kimatsuka, A., Ohnaka, I., Zhu, J.D., Sugiyama, A. & Kuroki, Y.(2006). Mold filling simulation for predicting gas porosity. IHI Engineering Review. 40(2), 83-88.
• [9] Yang, X., Huang, X., Dai, X., Campbell, J. & Tatler, J. (2004). Numerical modelling of entrainment of oxide film defects in filling of aluminium alloy castings. International Journal of Cast Metals Research, 17(6), 321-331. https://doi.org/10.1179/136404604225022748.
• [10] Dai, X., Jolly, M., Yang, X., & Campbell, J. (2012). Modelling of liquid metal flow and oxide film defects in filling of aluminium alloy castings. IOP Conference Series Materials Science and Engineering, 33(1), 2073.
• [11] Reilly, C., Green, N.R., Jolly, M.R. & Gebelin, J.C. (2013). The modelling of oxide film entrainment in casting systems using computational modelling. Applied Mathematical Modelling, 37(18-19), 8451-8466. https://doi.org/10.1016/j.apm.2013.03.061.
• [12] Reilly, C., Green, N.R. & Jolly, M.R. (2013). The present state of modeling entrainment defects in the shape casting process. Applied Mathematical Modelling. 37(3), 611-628. https://doi.org/10.1016/j.apm.2012.04.032.
• [13] Majidi, Hojjat, S., Beckermann, & Christoph. (2017). Modelling of air entrainment during pouring of metal castings. International Journal of Cast Metals Research. 30(5), 301-315. https://doi.org/10.1080/13640461.2017.1307624.
• [14] Cao, LiuLiao, DunmingSun, FeiChen, TaoTeng, ZihaoTang, Yulong. (2018). Prediction of gas entrapment defects during zinc alloy high-pressure die casting based on gas-liquid multiphase flow model. The International Journal of Advanced Manufacturing Technology. 94, 807-815. https://doi.org/10.1007/s00170-017-0926-5.

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024)