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EN
To prepare a high-quality asymmetrical bending pipe of aluminum alloy by casting, the parting surfaces of the asymmetrical parts were determined based on the characteristics of the parts. Also, the forming process was designed and calculated. After that, the different types of gating systems were designed and the casting process was calculated by ProCAST, and then the influence of different casting gating systems on asymmetrical bending pipes was analyzed. The simulation results show that in the solidification process, although the filling speed of the single runner was slow, but the filling was stable. The gating system with a single runner-round flange filling system would lead to being more uniform for filling flow field and be sequential solidification of temperature field distribution, and stronger of the feeding ability. During the solidification process, the solid phase ratio of the single runner-round flange casting system is larger, and the shrinkage volume is smaller, which made the quality of castings better. Finally, a metal mold and core were made to cast a perfect asymmetric bending pipe of aluminum alloy product in a die casting machine. So the single runner-round flange filling system is suitable for asymmetrical bending pipe casting.
EN
Computational Materials Engineering (CME) is a high technological approach used to design and develop new materials including the physical, thermal and mechanical properties by combining materials models at multiple techniques. With the recent advances in technology, the importance of microstructural design in CME environments and the contribution that such an approach can make in the estimation of material properties in simulations are frequently discussed in scientific, academic, and industrial platforms. Determination of the raw material characteristics that can be modeled in a virtual environment at an atomic scale by means of simulation programs plays a big role in combining experimental and virtual worlds and creating digital twins of the production chain and the products. In this study, a new generation, alternative and effective approach that could be used to the development of Al-Si based wheel casting alloys is proposed. This approach is based on the procedure of optimizing the physical and thermodynamic alloy properties developed in a computer environment with the CME technique before the casting phase. This article demonstrates the applicability of this approach in alloy development studies to produce Al-Si alloy wheels using the low pressure die casting (LPDC) method. With this study, an alternative and economical way is presented to the alloy development studies by trial and error in the aluminum casting industry. In other respects, since the study is directly related to the automotive industry, the reduction in fuel consumption in vehicles is an expected effect, as the new alloy aims to reduce the weight of the wheels. In addition to conserving energy, reducing carbon emissions also highlights the environmental aspects of this study.
EN
The research described in this contribution is focused on fractographic analysis of the fracture area of newly developed eutectic silumin type AlSi9NiCuMg0.5 (AA 4032), which was developed and patented by a team of staff of the Faculty of Mechanical Engineering. The paper presents determination of the cause of casting cracks in operating conditions. Fractographic analysis of the fracture area, identification of the structure of the casting, identification of structural components on the surface of the fracture surface and chemical analysis of the material in the area of refraction were performed within the experiment. Al-Si alloys with high specific strength, low density, and good castability are widely used in pressure-molded components for the automotive and aerospace industries. The results shown that the inter-media phases Fe-Al and Fe-Si in aluminium alloys lead to breakage across the entire casting section and a crack that crossed the entire cross section, which was confirmed by EDS analysis.
4
PL
W pracy przedstawiono wyniki badań procesu odlewania pod niskim ciśnieniem siluminowych kół samochodowych. Pokazano przebieg zmian temperatury odlewu i kokili w charakterystycznych jej punktach oraz sterowanie ciśnieniem siluminu i obwodami chłodzenia powietrzem. Zanalizowano cykl pracy maszyny niskociśnieniowej oraz wskazano kierunki dalszych prac zmierzających do optymalizacji cyklu odlewania i sterowania jakością odlewów kół samochodowych.
EN
The investigation results of low pressure casting process of car wheels casts was presented in the paper. It was shown the temperature characteristic of the die and the casting. The control of silumin pressure and air cooling system was shown too. It was analysed the work cycle of casting machine and managed the main directions the next investigations on the way the optimization of casting cycle and the quality control of the car wheel castings.
5
Content available remote Zdolność dwuskładnikowych stopów Al - Si do odwzorowania formy
PL
Przedstawiono wyniki badań zdolności aluminium i jego stopów z krzemem do odwzorowania formy. Przepływ realizowano w pionowym, metalowym kanale [średnica] 16 mm.
EN
The investigations results of mould surface reproducibility of aluminum and Al - Si alloys have been presented. The metal flow was realized in vertical metal channel of 16 mm diameter.
6
Content available remote Nowe stanowisko do badania lejności
PL
Przedstawiono stanowisko do badań lejności metali i stopów oparte na technologii odlewania niskociśnieniowego. Opisano nową koncepcję rejestracji przepływu metalu w kanale testowym.
EN
A new stand for the investigation of metals and alloys fluidity based on the low-pressure casting technology has been presented. A new concept of registration of the metal flow in a mould channel has been described.
PL
W artykule przedstawiono przykład zastosowania projektowania współbieżnego (Concurrent Engineering) do szybkiego opracowania w WSK "PZL-Rzeszów" S.A. technologii odlewania niskociśnieniowego odlewu, który był wykonywany przez innego producenta w technologii grawitacyjnej. Wykonaną w zaawansowanym systemie projektowym UNIGRAPHICS trójwymiarową geometrię odlewu oraz oprzyrządowania odlewniczego przekazano do systemu MAGMASOFT, który symuluje proces odlewania między innymi z uwzglęnieniem specyfiki odlewania niskociśnieniowego. Wyniki symulacji były podstawą do kolejnych modyfikacji technologii.
EN
In the article an example of application of concurrent engineering at WSK PZL-Rzeszów S.A. is given. The system was applied to enable rapid development of a low-pressure casting technology to manufacture en element which has so far been made by another manufacturer by the gravity die casting technology. The three-dimensional geometry of the casting made in the advanced design system UNIGRAPHICS as well as the foundry tooling have been transferred into the MAGMASOFT system which, among others, simulates the casting process, considering the specific features of the low-pressure casting process. The results of simulation were a basis for further modifications of this technology.
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