Novel riser designs via 3D sand printing to improve casting performance
Novel riser designs via 3D sand printing to improve casting performance
复制标题
通过 3D 砂打印进行新颖的冒口设计，以提高铸造性能
DOI：
10.1016/j.promfg.2021.06.052
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发表时间：
2021
期刊：
影响因子：
--
通讯作者：
Manogharan, Guha
中科院分区：
文献类型：
--
作者：
Shuvo, Md Moinuddin;Manogharan, Guha
3D砂型打印（3DSP）通过引入增材制造的复杂3D砂型和型芯，为砂型铸造应用开创了一个新时代。它还使设计和制造复杂的索具（浇口和进料）系统，使用非传统的设计规则，这是以前不可行的。本文研究了两种新型冒口设计--椭圆形冒口和球形冒口，沿着采用传统的圆柱形冒口，以了解它们对铝合金（A319）铸件凝固时间和夹杂空气体积分数的影响。计算模拟，了解复杂的冒口形状的可行性，通过比较关键参数，如流体温度在填充，凝固和冷却。此外，还研究了充型和凝固过程中的固相率和引气率。球形冒口性能的结果表明，在凝固过程中的补缩时间增加了7%，沿着的夹带空气体积分数减少了47.27%。在本研究中所研究的椭圆形冒口也显示出相同的凝固时间在传统的圆柱形冒口的一半体积。这表明铸造产量增加了26.5%。这些冒口设计不仅有利于铸件的设计优化，而且还改善了难以铸造的材料和几何形状的铸造性能（补缩、凝固）。
3D sand printing (3DSP) has created a new era for sand casting applications by introducing additively manufactured complex 3D sand molds and cores. It has also enabled the design and manufacturing of complex rigging (gating and feeding) systems using non-conventional design rules which were not previously feasible. In this research, two novel riser designs, ellipsoid and spherical risers, along with traditional cylindrical risers are investigated to understand their effects on the solidification time and entrained air volume fraction in Aluminum alloy (A319) castings. Computational simulations are presented to understand the viability of complex riser shapes by comparing critical parameters such as fluid temperature during filling, solidification, and cooling. In addition, solid fraction (SF) and entrained air volume fraction are also studied during filling and solidification. The results for spherical riser performance showed a 7% increase in feeding time during solidification along with a 47.27% reduction in entrained air volume fraction. The ellipsoid riser studied in this research also showed identical solidification time at half the volume of the conventional cylindrical riser. This indicated a 26.5% increase in casting yield. These riser designs will not only facilitate the design optimization of the casting but also improve the casting performance (feeding, solidification) for difficult to cast materials and geometries.
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