optimization of ingot geometry casting technology

optimization of ingot geometry casting technology

3D SPH SIMULATIONS OF THE ALUMINIUM INGOT

The simulations were carried out to produce ingots at the rate of 30 tonnes/hr. The synchronised linear ingot mould bank speed was 6 m/min. The rotational speed of the ingot wheel was adjusted accordingly. Seven different wheel geometries were simulated. The base case wheel design (Figure 2) was also simulated with an ingot casting rate of

3D SPH SIMULATIONS OF THE ALUMINIUM INGOT

The simulations were carried out to produce ingots at the rate of 30 tonnes/hr. The synchronised linear ingot mould bank speed was 6 m/min. The rotational speed of the ingot wheel was adjusted accordingly. Seven different wheel geometries were simulated. The base case wheel design (Figure 2) was also simulated with an ingot casting rate of Abstract ICRF 2018 - 3rd ICRF ConferenceOptimization of casting technology, chemical composition, and ingot geometry of a 20 tones 42crmo4 ingot to minimize macrosegregation and increase material homogeneity Ovidiu Bogdan Industrial Soft

Abstract ICRF 2018

Optimization of casting technology, chemical composition, and ingot geometry of a 20 tones 42crmo4 ingot to minimize macrosegregation and increase material homogeneity Ovidiu Bogdan Industrial Soft Automatic Virtual Optimization of Ingot and Optimization of Ingot Casting Process . Most major quality problems in ingots originate from the casting process. Defects like shrinkage, porosity, segregation, non-metallic inclusions and cracks are initiated during teeming of the liquid steel and/or during solidification in the mould. There are various parameters of the casting process that can be

BRACH · Engineering & Material Technology

BRACH Engineering & Material Technology your partner for material technology and special purpose machinery. Our core competencies are the development and optimization of casting processes for ingot casting.Using various techniques, we improve the quality of the ingot and increase the life of the mold. Gladly we test and optimize your mold geometries and materials, analyze their casting CASTING SIMULATION SUITEof investment casting foundries like allowing for non-uniform shell thickness to be blended and multiple shell layers to be created. Also, radiation with view factors, including shadowing effects, which are critical for high temperature alloys, are taken into account. Sand Casting The key to success in a Sand Casting foundry is the optimization of

Casting Technologies - INTECO melting and casting

Vacuum Ingot Casting; In case of Bottom Pouring the ingots are teemed via a trumpet from the bottom into the mould. This technology is used for all types of ingots up to 160t in the shape. For bigger ingots from 120 up to 700 t the Vacuum Ingot Casting is used. The reason for this technology is to prevent any increase of the hydrogen content Casting Technology and Quality Improvement of casting process from the standpoint of productivity, cost effectiveness, and final ingot quality. One of the challenges in optimization is the complex interaction between the casting parameters, such as withdrawal rate, water flow rate, dummy block design, and defect formation, which is

Development of steel ingot casting technology

Such technical features as multi-ladle casting, optimization of ingot geometry, optimization of chemical composition of cast metal, mastering of hollow ingot production, jet vacuum processing, bottom casting of large ingots, materials for insulation of feeder head, protection of secondary oxidizing and accelerated cooling conditions are examined. Development of steel ingot casting technologyThe paper presents the history of mastering of large ingot steel casting and prospective technological approaches used in ingot casting of high-quality steel. Such technical features as multi-ladle casting, optimization of ingot geometry, optimization of chemical composition of cast metal, mastering of hollow ingot production, jet vacuum processing, bottom casting of large ingots, materials

Forging Quality in Steel Ingot Manufacturing & Conversion

Apr 15, 2015 · Casting process parameters Hot work while converting to bar Incoming Workpiece& Die Geometry Further Optimization. Conclusions Using advanced modeling tools, TimkenSteel can bypass the use of reduction ratio and focus on optimizing Gating system optimization of low pressure casting Gating system optimization of low pressure casting A356 aluminum alloy intake manifold based on numerical simulation * Jiang Wenming Male, born in 1982, Ph.D. Research interest:precision casting technology of non-ferrous alloy. E-mail:[email protected] Received:2013-06-15 Accepted:2013-12-12 *Jiang Wenming 1, 2 and Fan Zitian 2 1.

MAIN TRENDS IN THE DEVELOPMENT OF -

Optimizing the geometry of the ingots. Changing the geometry of ingots makes it possible to effectively control the parameters that characterize their chemical, physical, and structural nonuniformity. However, due to the countervailing effects Year Weight of ingot, tons Geometric characteristics Manufacturer H/D conicity, % hot top, % Main Trends in the Development of Technology for Casting Sep 22, 2013 · This article discusses promising technological measures that can be used to cast ingots. It also examines such issues as multi-ladle casting, optimization of ingot geometry and the chemical composition of the metal being cast, mastery of the production of hollow ingots, stream vacuum-degassing, aspects of the bottom-pouring of large ingots, materials for warming the hot-top part of ingots, protection from secondary oxidation, and high-speed casting.

Main Trends in the Development of Technology for Casting

This article discusses promising technological measures that can be used to cast ingots. It also examines such issues as multi-ladle casting, optimization of ingot geometry and the chemical Melting, Remelting, and Casting for Clean Steel - Campbell Continuous casting contrasts with ingot casting which is more appropriate to the production of smaller batches of special steels. However, the current ingot pouring practice is far from satisfactory, but which appears to be universal as far as the author can ascertain. A schematic illustration of ingot casting is shown in Figure 9a. When full

Modeling and Optimization of Direct Chill Casting to

FINAL TECHNICAL REPORT Project Title:Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking Award No.:DE-FC36-00ID97 Project Period:September 2000April 2005 PI:Dr. Subodh K. Das (Secat, Inc.) Phone:859-514-4955 E-mail:[email protected] Additional Researchers:Dr. Qingyou Han (ORNL) Dr. Srinath Viswanathan (ORNL, Univ. of Alabama) Modeling and Optimization of Direct Chill Casting to FINAL TECHNICAL REPORT Project Title:Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking Award No.:DE-FC36-00ID97 Project Period:September 2000April 2005 PI:Dr. Subodh K. Das (Secat, Inc.) Phone:859-514-4955 E-mail:[email protected] Additional Researchers:Dr. Qingyou Han (ORNL) Dr. Srinath Viswanathan (ORNL, Univ. of Alabama)

Modeling and optimization of porous silica ingot melting

Feb 25, 2018 · Modeling and optimization of porous silica ingot melting during quartz glass synthesis. silica or vycor glass, is a specific type of glass widely used in semiconductor, light source, laser system, space technology, and atomic industry, The diameter and height of the simulation geometry are both L. Modeling of Initial Mold Filling in Uphill Teeming Process The proportion of ingot casting only makes up a small fraction of total steel productions. The ingot production in the world has also decreased to 7.0% of the total crude steel production in 2007, which comprises of 94.704 million metric tons.1) However, ingot casting is a crucial

Multi-objective Optimization of Die Geometry in Ingot

In order to replicate a typical casting defect along the centre line of the ingot the centre region of the ingot is assumed to have a relative density R=0.25 up within a radius of 100mm, followed by an annular region of 200mm radius, where R increases linearly up to 0.9. The remaining geometry of the ingot is assumed to be fully dense. Multi-objective Optimization of Die Geometry in Ingot In order to replicate a typical casting defect along the centre line of the ingot the centre region of the ingot is assumed to have a relative density R=0.25 up within a radius of 100mm, followed by an annular region of 200mm radius, where R increases linearly up to 0.9. The remaining geometry of the ingot is assumed to be fully dense.

NUMERICAL MODELLING OF MACROSEGREGATION IN

geometry of the casting system is shown in Fig. 1 [14]. Fig. 1. Comparison of the real and CAD geometry of the casting system of a 90-ton ingot [15] The Optimization of flow and solidification for the casting of Measures for the optimization of the ingot casting process were elaborated. Geometry of the selected feeding systems Fig. 1-Geometria del sistema di alimentazione selezionato

Optimization of ingot geometry, casting technology

Optimization of Ingot Geometry - H/D ratio, Ingot Taper, Hot Top Size Optimization of Casting technology - Pouring Temperature, Exothermic Material Optimization of Chemical Composition - C, Si, Mn, Cr, Mo Conclusions 2, 3 Macrosegregation in steel ingots Sulfur print in sectioned ingots Optimization of power consumption on silicon directional Sep 01, 2012 · Directional solidification system (DSS) is the most commonly used casting station in the solar industry. To lower the manufacturing cost has been a consistent request in industry. A geometry modification has been made on silicon directional solidification system in order to save energy. It has been shown to be effective from experimental data.

Optimization of power consumption on silicon directional

Sep 01, 2012 · Directional solidification system (DSS) is the most commonly used casting station in the solar industry. To lower the manufacturing cost has been a consistent request in industry. A geometry modification has been made on silicon directional solidification system in order to save energy. It has been shown to be effective from experimental data. PREDICTION OF CASTING AND SOLIDIFICATION OF 2.1 Geometry and FEM mesh The whole 3D ingot geometry was created in the CAD system SolidWorks. The CAD geometry of the casting system is shown in Fig.1. In our case, only one type of computational mesh for calculation of filling and solidification was used and we calculated the whole process in one step. The final surface and volume

Page 1 from 14 Optimization of ingot - Industrial Soft

In order to analyze A-segregation and optimize the ingot geometry, casting variables and chemical composition we have developed Ingot Mold Design Assistant v.1.0, the solidification simulation software SIMCADE v.2.0 and a mathematical model to evaluate the critical value at which the A-segregation begin to appear. 2.1 Ingot and mold design QUALITY PREDICTION THROUGH COMBINED design and optimization, including forging. Simulation enables virtual trials with nearly unlimited observation possibilities. Using casting process simulation, it is possible to teem, solidify and cool an ingot in a virtual casting process to predict e.g. shrinkage, centre

SETTING A NUMERICAL SIMULATION OF FILLING AND

verification and optimization of the production technology for the heavy-steel ingots produced in VÍTKOVICE HEAVY MACHINERY a.s. The input parameters of the computation were determined with the real conditions of casting a 90-ton steel ingot. The ingot geometry was created in the CAD system SolidWorks. Before the computational grid generation Simulation of ingot casting processes at Deutsche Jan 12, 2012 · To enhance the quality of tool steels it is necessary to analyse all stages of the production process. During the ingot- or continuous casting processes and the following solidification, material and geometry depending reactions cause defects such as macro segregations or porosities.

Simulation of ingot casting processes at Deutsche

Jan 12, 2012 · To enhance the quality of tool steels it is necessary to analyse all stages of the production process. During the ingot- or continuous casting processes and the following solidification, material and geometry depending reactions cause defects such as macro segregations or porosities. Special Issue "Optimization of Industrial Casting Processes"In the context of casting technology, and for a given alloy chemistry, optimization may be thought of as obtaining a desired design objective(s) through manipulation of the process parameters and/or altering the geometry of the mould system.

TECHNOLOGY OPTIMIZATION OF CONTINUOUS

weight of 1 running meter is 21.5% less, than the area of a square ingot with the side, equal to the diameter of the round ingot. Therefore, the production rate of a strand while casting the round billet and the square with a side, equal to the diameter, is almost the same. However, in case of continuous casting of round billets, especially The effect of boundary conditions of casting on the size Abstract. Purpose:The paper presents new knowledge from numerical modelling of porosity in heavy steel ingot using ProCAST software. The main aim of numerical modelling realized under the conditions of the Department of Metallurgy and Foundry and Regional Materials Science and Technology Centre at the VSB-TU Ostrava is the optimization of the production of heavy steel ingots produced at the

Optimization of ingot geometry , casting technology

The goal of this work was to choose the optimum ingot geometry, casting technology variables and chemical composition in order to avoid or reduce segregation and increase the homogeneity of a 42CrMo4 20 tons ingot.

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