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Using simulation to predict defects in and cast Al-alloy castings
Šolc, Petr ; Bařinová, Dagmar (referee) ; Čech, Jaroslav (advisor)
The aim of this work is comparing three casting process simulation programs for porosity and microstructure prediction capabilities for die-casting. After confronting these results with experimentally measured data taken from real castings it could be said that simulation is pretty accurate for DAS microstructure prediction and hot-spot areas. Amount of measured porosity could not be compared with predicted values because specimens were not taken from the exact hot-spot areas.
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Optimization of aluminium casting process using numerical simulation
Kolařík, Martin ; Lána, Ivo (referee) ; Krutiš, Vladimír (advisor)
The master’s thesis deals with the analysis of casting technology of the selected aluminium casting. It is a casting of a part of CNC milling machine and it is cast by gravity casting into a permanent mold. The defects which are the cause of a high percentage of nonconforming production were analyzed. Furthermore, the master’s thesis includes a complete analysis of filling and solidification of this casting in the ProCast simulation program. Numerical simulation results are verified and improved. Then the causes of problematic casting defects are proven on several calculated variants. Measures are proposed to minimize the tendency to produce castings with defects leading to nonconforming production.
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Use of Numerical Simulation to Optimize Wax Patterns Production
Kosour, Vojtěch ; Elbel, Tomáš (referee) ; Nová, Iva (referee) ; Horáček, Milan (advisor)
Production of wax pattern model by injection machine is a one of the key phases of Investment casting process. The thesis deals with the development of numerical simulation wax blend injection in to metal die. The possibilities of selection simulation software – ProCast and Cadmould are described in the relation to numerical predictions of wax injection. Creating of material database of selected wax blends is described. The prototype simulations of die filling are made. The special testing die are designed a used for created simulations. The measurements of initial conditions are mentioned.
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RP technology using FDM method and investment casting technology
Kosour, Vojtěch ; Krutiš, Vladimír (referee) ; Horáček, Milan (advisor)
An overview of the development of the Investment Casting market and Rapid Prototyping equipment is given in the introductory part of this diploma thesis. Basic methods of rapid prototyping and the FDM method are futher described in detail. The FDM method is consequently used in the practical part of this work for the preparation of the silicon mould. The largest part deals with the issue of the simulation of pouring process of wax into the silicon mould. A characteristics of the casting wax is made; the parametres, which are inserted into the simulation software ProCAST and the possibilities of their measurement are described. The process of the simulation of the mould filling and its validation with the real filling process are described in detail.
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Influence of exothermic sleaves on solidification of aluminium alloys
Zajíček, Roman ; Krutiš, Vladimír (referee) ; Roučka, Jaromír (advisor)
The master’s thesis deals with the influence of the exothermic risers on the solidification of aluminum alloys. The work is divided into three parts. The first theoretical part describes the differences of properties of cast aluminum alloys compared to other based metals, especially iron alloys. It also describes the methodology of designing risers, composition of exothermic mixtures and finally gives an overview on the simulation programs on the market, their application in foundry practice and briefly explains how to define the material in the simulation program ProCAST. The second part describes the experimental measurement of the solidification time of aluminum alloy AlSi7Mg0,3 in the sand form with exothermic riser. The final section describes the simulation of experimental measurements. Further with help of simulation software it is tried to find the general principles that have an influence on feed module rate of exothermic riser.
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Optimization of aluminium casting process using numerical simulation
Kolařík, Martin ; Lána, Ivo (referee) ; Krutiš, Vladimír (advisor)
The master’s thesis deals with the analysis of casting technology of the selected aluminium casting. It is a casting of a part of CNC milling machine and it is cast by gravity casting into a permanent mold. The defects which are the cause of a high percentage of nonconforming production were analyzed. Furthermore, the master’s thesis includes a complete analysis of filling and solidification of this casting in the ProCast simulation program. Numerical simulation results are verified and improved. Then the causes of problematic casting defects are proven on several calculated variants. Measures are proposed to minimize the tendency to produce castings with defects leading to nonconforming production.
|
|
|
Influence of exothermic sleaves on solidification of aluminium alloys
Zajíček, Roman ; Krutiš, Vladimír (referee) ; Roučka, Jaromír (advisor)
The master’s thesis deals with the influence of the exothermic risers on the solidification of aluminum alloys. The work is divided into three parts. The first theoretical part describes the differences of properties of cast aluminum alloys compared to other based metals, especially iron alloys. It also describes the methodology of designing risers, composition of exothermic mixtures and finally gives an overview on the simulation programs on the market, their application in foundry practice and briefly explains how to define the material in the simulation program ProCAST. The second part describes the experimental measurement of the solidification time of aluminum alloy AlSi7Mg0,3 in the sand form with exothermic riser. The final section describes the simulation of experimental measurements. Further with help of simulation software it is tried to find the general principles that have an influence on feed module rate of exothermic riser.
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Use of Numerical Simulation to Optimize Wax Patterns Production
Kosour, Vojtěch ; Elbel, Tomáš (referee) ; Nová, Iva (referee) ; Horáček, Milan (advisor)
Production of wax pattern model by injection machine is a one of the key phases of Investment casting process. The thesis deals with the development of numerical simulation wax blend injection in to metal die. The possibilities of selection simulation software – ProCast and Cadmould are described in the relation to numerical predictions of wax injection. Creating of material database of selected wax blends is described. The prototype simulations of die filling are made. The special testing die are designed a used for created simulations. The measurements of initial conditions are mentioned.
|
|
|
Using simulation to predict defects in and cast Al-alloy castings
Šolc, Petr ; Bařinová, Dagmar (referee) ; Čech, Jaroslav (advisor)
The aim of this work is comparing three casting process simulation programs for porosity and microstructure prediction capabilities for die-casting. After confronting these results with experimentally measured data taken from real castings it could be said that simulation is pretty accurate for DAS microstructure prediction and hot-spot areas. Amount of measured porosity could not be compared with predicted values because specimens were not taken from the exact hot-spot areas.
|
|
|
RP technology using FDM method and investment casting technology
Kosour, Vojtěch ; Krutiš, Vladimír (referee) ; Horáček, Milan (advisor)
An overview of the development of the Investment Casting market and Rapid Prototyping equipment is given in the introductory part of this diploma thesis. Basic methods of rapid prototyping and the FDM method are futher described in detail. The FDM method is consequently used in the practical part of this work for the preparation of the silicon mould. The largest part deals with the issue of the simulation of pouring process of wax into the silicon mould. A characteristics of the casting wax is made; the parametres, which are inserted into the simulation software ProCAST and the possibilities of their measurement are described. The process of the simulation of the mould filling and its validation with the real filling process are described in detail.
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