To predict the segregation effect in metal injection moulding (MIM) injection, a bi-phasic model based on mixture theory is adopted in simulation. An explicit algorithm is developed and realized by the authors, which ...To predict the segregation effect in metal injection moulding (MIM) injection, a bi-phasic model based on mixture theory is adopted in simulation. An explicit algorithm is developed and realized by the authors, which conducts the simulation to be a cost-effective tool in MIM technology. In case of the bi-phasic simulation, the viscosity behaviours are necessary to be determined for the flows of each phase while only the viscosity of mixture is measurable by tests. It is a crucial problem for application of the bi-phasic simulation of MIM injection. A reasonable method is hence analysed and proposed to determine the viscosity behaviours of each phase. Even though this method may be furthermore modified in the future, it results in the practical simulation of segregation effects with reasonable parameters. The simulation results are compared with the measurements on injected specimens.展开更多
A process to convert models made by rapid prototypi ng techniques like SL (stereolitography) and LOM (laminated object manufacturing) or by conventional techniques (silicones, resins, wax, etc.) into metallic mould s ...A process to convert models made by rapid prototypi ng techniques like SL (stereolitography) and LOM (laminated object manufacturing) or by conventional techniques (silicones, resins, wax, etc.) into metallic mould s or tools has been developed. The main purpose of this technique is to rapidly obtain the first prototypes of parts, for plastics injection, forging or any oth er manufacturing process using the tools produced by casting a metal into a cera mic mould. Briefly, it can be said that the ceramic moulds are produced by mixing in variab le proportions, depending on the type of ceramics employed, strength and roughne ss desired, a ceramic mixture composed by alumina and/or zirconium silicates bon ded with silica coming from a liquid binder, based on ethyl silicate. A catalyst is added to the slurry in order to produce a sol-gel reaction. The liquid slur ry is poured into the box containing the mould to be reproduced. After a short p eriod of time, controlled by the amount of gelling agent, the ceramic mixture ac quires a rubber consistency. The pattern is removed from the ceramic mould, whic h is fired to stop the gelation reaction. After this stabilization the ceramic m ould is sintered at high temperatures in order to generate an inert mould wi th the desired strength in which almost all metallic alloys can be cast. The effect of ceramic materials (shape, granulometric distribution, chemical com position, etc.), processing parameters (proportion binder/ceramic/catalyst, sint ering conditions, etc.) and casting conditions (mould pre-heating temperature a nd pouring temperature) were studied in order to obtain metallic moulds or tools with tailored properties (high dimensional accuracy, low roughness and high mec hanical strength).展开更多
This paper presents a technique for controlling the pressure of a molten metal when using a new type of iron casting method called sand mold press casting to realize high productivity and obtain high-quality products....This paper presents a technique for controlling the pressure of a molten metal when using a new type of iron casting method called sand mold press casting to realize high productivity and obtain high-quality products.The past test results using this method showed a casting yield of 90% to 95%,while conventional methods only show a casting yield of 60% to 70%.Although the press casting method does not require a sprue cup or runner channel casting defects such as metal penetration are often caused by the high pressure in the high-velocity pressing part of this casting process.Therefore,we proposed a pressure control method with a mathematical model of molten metal pressure,and with it we achieved experimental confirmation of the successful production of brake drums at different pressing temperatures.Results show that the proposed pressing control method can realize sound,penetration-free casting production.However,the theoretical analysis and design of this pressing process had not previously been studied sufficiently,and therefore this paper presents the theoretical design algorithm for the process as well as its experimental confirmation.展开更多
The bulk Fe<sup>60 CoxZr<sup>10 Mo5W2B<sup>23-x （x=1, 3, 5, 7, 9） amorphous rods with diameters of 1.5 mm were successfully prepared by copper mold casting method with the low purity raw materials....The bulk Fe<sup>60 CoxZr<sup>10 Mo5W2B<sup>23-x （x=1, 3, 5, 7, 9） amorphous rods with diameters of 1.5 mm were successfully prepared by copper mold casting method with the low purity raw materials. The amorphous and crystalline states, and thermal parameters, such as the glass transition temperature （Tg）, the initial crystallization temperature （Tx）, the supercooled liquid region （ΔTx=Tx-Tg）, the reduced glass transition temperature T<sup>rg （Tg/Tm, Tm: the onset temperature of melting of the alloy, and Tg/Tl, Tl: the finished temperature of melting of the alloy） were investigated by X-ray diffractometry （XRD） and differential scanning calorimetry （DSC） analysis. Glass forming ability of Fe<sup>60 CoxZr<sup>10 Mo5W2B<sup>23-x （x=1,3,5,7,9） bulk metallic glasses has been studied. According to the results, the alloy （x=7） with the highest T<sup>rg （Tg/Tl=0.607, Tg/Tl=0.590） value, has the strongest glass forming ability among these alloys because its composition is near eutectic composition. The wide supercooled liquid region over 72 K indicates the high thermal stability for this alloy system. This bulk metallic glass exhibits quite high strength （Hv 1020）. The success of production of the Fe-based bulk metallic glass with industrial materials is of great significance for the future progress of basic research and practical application.展开更多
We investigated the deformation behaviors of Zr_65Cu_17.5Ni_10Al_7.5 in superplastic forming in silicon mould via numerical modeling and experiments. The data needed for the constitutive formulation were obtained from...We investigated the deformation behaviors of Zr_65Cu_17.5Ni_10Al_7.5 in superplastic forming in silicon mould via numerical modeling and experiments. The data needed for the constitutive formulation were obtained from compressive tests to establish a material library for finite-element simulation using a DEFORM 3D software. A constant speed forming process of a micro gear was modeled where the loading force, feature size and amount of deformation in the micro gear in silicon mould were analyzed in detail for the optimal requirements of micro gear forming and the protection of silicon mould. Guided by the modeling parameters, an amorphous metal micro gear was successfully obtained by our home-made superplastic forming system with the optimized parameters （temperature of 683 K, top speed of 0.003 mm/s until the load force reaching limiting value at 1960 N, and a gradually decelerating process for holding the force to the end）. Our work gives a good example for optimization of superplastic forming and fabrication of BMGs in microparts.展开更多
文摘To predict the segregation effect in metal injection moulding (MIM) injection, a bi-phasic model based on mixture theory is adopted in simulation. An explicit algorithm is developed and realized by the authors, which conducts the simulation to be a cost-effective tool in MIM technology. In case of the bi-phasic simulation, the viscosity behaviours are necessary to be determined for the flows of each phase while only the viscosity of mixture is measurable by tests. It is a crucial problem for application of the bi-phasic simulation of MIM injection. A reasonable method is hence analysed and proposed to determine the viscosity behaviours of each phase. Even though this method may be furthermore modified in the future, it results in the practical simulation of segregation effects with reasonable parameters. The simulation results are compared with the measurements on injected specimens.
文摘A process to convert models made by rapid prototypi ng techniques like SL (stereolitography) and LOM (laminated object manufacturing) or by conventional techniques (silicones, resins, wax, etc.) into metallic mould s or tools has been developed. The main purpose of this technique is to rapidly obtain the first prototypes of parts, for plastics injection, forging or any oth er manufacturing process using the tools produced by casting a metal into a cera mic mould. Briefly, it can be said that the ceramic moulds are produced by mixing in variab le proportions, depending on the type of ceramics employed, strength and roughne ss desired, a ceramic mixture composed by alumina and/or zirconium silicates bon ded with silica coming from a liquid binder, based on ethyl silicate. A catalyst is added to the slurry in order to produce a sol-gel reaction. The liquid slur ry is poured into the box containing the mould to be reproduced. After a short p eriod of time, controlled by the amount of gelling agent, the ceramic mixture ac quires a rubber consistency. The pattern is removed from the ceramic mould, whic h is fired to stop the gelation reaction. After this stabilization the ceramic m ould is sintered at high temperatures in order to generate an inert mould wi th the desired strength in which almost all metallic alloys can be cast. The effect of ceramic materials (shape, granulometric distribution, chemical com position, etc.), processing parameters (proportion binder/ceramic/catalyst, sint ering conditions, etc.) and casting conditions (mould pre-heating temperature a nd pouring temperature) were studied in order to obtain metallic moulds or tools with tailored properties (high dimensional accuracy, low roughness and high mec hanical strength).
文摘This paper presents a technique for controlling the pressure of a molten metal when using a new type of iron casting method called sand mold press casting to realize high productivity and obtain high-quality products.The past test results using this method showed a casting yield of 90% to 95%,while conventional methods only show a casting yield of 60% to 70%.Although the press casting method does not require a sprue cup or runner channel casting defects such as metal penetration are often caused by the high pressure in the high-velocity pressing part of this casting process.Therefore,we proposed a pressure control method with a mathematical model of molten metal pressure,and with it we achieved experimental confirmation of the successful production of brake drums at different pressing temperatures.Results show that the proposed pressing control method can realize sound,penetration-free casting production.However,the theoretical analysis and design of this pressing process had not previously been studied sufficiently,and therefore this paper presents the theoretical design algorithm for the process as well as its experimental confirmation.
文摘The bulk Fe<sup>60 CoxZr<sup>10 Mo5W2B<sup>23-x （x=1, 3, 5, 7, 9） amorphous rods with diameters of 1.5 mm were successfully prepared by copper mold casting method with the low purity raw materials. The amorphous and crystalline states, and thermal parameters, such as the glass transition temperature （Tg）, the initial crystallization temperature （Tx）, the supercooled liquid region （ΔTx=Tx-Tg）, the reduced glass transition temperature T<sup>rg （Tg/Tm, Tm: the onset temperature of melting of the alloy, and Tg/Tl, Tl: the finished temperature of melting of the alloy） were investigated by X-ray diffractometry （XRD） and differential scanning calorimetry （DSC） analysis. Glass forming ability of Fe<sup>60 CoxZr<sup>10 Mo5W2B<sup>23-x （x=1,3,5,7,9） bulk metallic glasses has been studied. According to the results, the alloy （x=7） with the highest T<sup>rg （Tg/Tl=0.607, Tg/Tl=0.590） value, has the strongest glass forming ability among these alloys because its composition is near eutectic composition. The wide supercooled liquid region over 72 K indicates the high thermal stability for this alloy system. This bulk metallic glass exhibits quite high strength （Hv 1020）. The success of production of the Fe-based bulk metallic glass with industrial materials is of great significance for the future progress of basic research and practical application.
基金Funded by the National Natural Science Foundation of China(Nos.51222508,51175211)
文摘We investigated the deformation behaviors of Zr_65Cu_17.5Ni_10Al_7.5 in superplastic forming in silicon mould via numerical modeling and experiments. The data needed for the constitutive formulation were obtained from compressive tests to establish a material library for finite-element simulation using a DEFORM 3D software. A constant speed forming process of a micro gear was modeled where the loading force, feature size and amount of deformation in the micro gear in silicon mould were analyzed in detail for the optimal requirements of micro gear forming and the protection of silicon mould. Guided by the modeling parameters, an amorphous metal micro gear was successfully obtained by our home-made superplastic forming system with the optimized parameters （temperature of 683 K, top speed of 0.003 mm/s until the load force reaching limiting value at 1960 N, and a gradually decelerating process for holding the force to the end）. Our work gives a good example for optimization of superplastic forming and fabrication of BMGs in microparts.
