An integration system was developed to satisfy the need of information integration in the process of designing, investment casting and monitoring aero-engine's turbo blade. The general architecture is detailed pre...An integration system was developed to satisfy the need of information integration in the process of designing, investment casting and monitoring aero-engine's turbo blade. The general architecture is detailed presented in this paper. The system mainly comprises of product master model, design information management, anti-deformation design of mould cavity, intelligence mould design and blade testing. The developed system can manage mould design and blade test data flow, optimize mould design process and achieve the goal of integration design.展开更多
To make high integrity lightweight metal castings,best practices are required in various stages of casting and heat treatment processes,including liquid metal composition and quality control,casting and gating/riser s...To make high integrity lightweight metal castings,best practices are required in various stages of casting and heat treatment processes,including liquid metal composition and quality control,casting and gating/riser system design,and process optimization.This paper presents best practices for liquid metal processing and quality assurance of molten metal in both melting and mold filling.Best practices for other aspects of lightweight metal casting will be published separately.展开更多
Construction of integrated database including casting shapes with their casting design, technical knowledge, and thermophysical properties of the casting alloys were introduced in the present study. Recognition tech- ...Construction of integrated database including casting shapes with their casting design, technical knowledge, and thermophysical properties of the casting alloys were introduced in the present study. Recognition tech- nique for casting design by industrial computer tomography was used for the construction of shape database. Technical knowledge of the casting processes such as ferrous and non-ferrous alloys and their manufacturing process of the castings were accumulated and the search engine for the knowledge was developed. Database of thermophysical properties of the casting alloys were obtained via the experimental study, and the properties were used for the in-house computer simulation of casting process. The databases were linked with intelligent casting expert system developed in center for e-design, KITECH. It is expected that the databases can help non casting experts to devise the casting and its process. Various examples of the application by using the databases were shown in the present study.展开更多
With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of...With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of the digital management aspect in precision casting enterprises, and puts forward three corresponding techniques. They are: the production process tracking card technology based on the main-sub card mode; the workshop site production process processing technology based on the barcode; and the equipment data integration technology. Then, this paper discusses in detail the principle, application and effect of these technologies; to provide the reference for enterprises to move towards digital casting and intelligent casting.展开更多
Compared to traditional high-pressure die casting(HPDC),horizontal squeeze casting(HSC)is a more promising way to fabricate high-integrity castings,owing to a reduced number of gas and shrinkage porosities produced in...Compared to traditional high-pressure die casting(HPDC),horizontal squeeze casting(HSC)is a more promising way to fabricate high-integrity castings,owing to a reduced number of gas and shrinkage porosities produced in the casting.In this paper,the differences between HSC and HPDC are assessed,through which it is shown that the cavity filling velocity and the size of the gating system to be the most notable differences.Equipment development and related applications are also reviewed.Furthermore,numerical simulation is used to analyze the three fundamental characteristics of HSC:slow cavity filling,squeeze feeding and slow sleeve filling.From this,a selection principle is given based on the three related critical casting parameters:cavity filling velocity,gate size and sleeve filling velocity.Finally,two specific applications of HSC are introduced,and the future direction of HSC development is discussed.展开更多
The interior of a high-pressure die-casting is of an unsatisfactory quality. Engine blocks made with this die casting process show lower specific engine performance. Pressure die-casting can hardly be heat treated for...The interior of a high-pressure die-casting is of an unsatisfactory quality. Engine blocks made with this die casting process show lower specific engine performance. Pressure die-casting can hardly be heat treated for obvious reasons. PSM (Precision Sand Molds) process uses sand and organic binder to generate a mold and even allows the manufacturing of complex diesel engine blocks in aluminum alloys. Combined technologies are available for semi-permanent mold castings with cores and castings made in Precision Sand Molds with organic binders. Castings are placed into the special heat treatment furnace immediately after pouring without the operations in stand alone machinery. This patented Sand Lion 3- in-1 technology processes hot castings and carries out three (3) foundry processes simultaneously in one (1) automated machine: 1) De-coring and sand removal; 2) Thermal sand reclamation; 3) Solution heat treatment of castings. The combination of several main casting processes is reflected in significant reductions of energy consumption, of production costs, and improving the quality of the castings. Audits in foundries using the 3-in-l process showed an average reduction in production costs of more than 30%.展开更多
基金National High-tech R&D Program (863 Program) (2006AA04Z144)Key Technologies R&D Program (2006BAF04B02).
文摘An integration system was developed to satisfy the need of information integration in the process of designing, investment casting and monitoring aero-engine's turbo blade. The general architecture is detailed presented in this paper. The system mainly comprises of product master model, design information management, anti-deformation design of mould cavity, intelligence mould design and blade testing. The developed system can manage mould design and blade test data flow, optimize mould design process and achieve the goal of integration design.
文摘To make high integrity lightweight metal castings,best practices are required in various stages of casting and heat treatment processes,including liquid metal composition and quality control,casting and gating/riser system design,and process optimization.This paper presents best practices for liquid metal processing and quality assurance of molten metal in both melting and mold filling.Best practices for other aspects of lightweight metal casting will be published separately.
文摘Construction of integrated database including casting shapes with their casting design, technical knowledge, and thermophysical properties of the casting alloys were introduced in the present study. Recognition tech- nique for casting design by industrial computer tomography was used for the construction of shape database. Technical knowledge of the casting processes such as ferrous and non-ferrous alloys and their manufacturing process of the castings were accumulated and the search engine for the knowledge was developed. Database of thermophysical properties of the casting alloys were obtained via the experimental study, and the properties were used for the in-house computer simulation of casting process. The databases were linked with intelligent casting expert system developed in center for e-design, KITECH. It is expected that the databases can help non casting experts to devise the casting and its process. Various examples of the application by using the databases were shown in the present study.
基金financially supported by the National Science&Technology Key Projects of Numerical Control(2012ZX04012-011)National High-tech R&D Program(863 program)(2013031003)
文摘With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of the digital management aspect in precision casting enterprises, and puts forward three corresponding techniques. They are: the production process tracking card technology based on the main-sub card mode; the workshop site production process processing technology based on the barcode; and the equipment data integration technology. Then, this paper discusses in detail the principle, application and effect of these technologies; to provide the reference for enterprises to move towards digital casting and intelligent casting.
文摘Compared to traditional high-pressure die casting(HPDC),horizontal squeeze casting(HSC)is a more promising way to fabricate high-integrity castings,owing to a reduced number of gas and shrinkage porosities produced in the casting.In this paper,the differences between HSC and HPDC are assessed,through which it is shown that the cavity filling velocity and the size of the gating system to be the most notable differences.Equipment development and related applications are also reviewed.Furthermore,numerical simulation is used to analyze the three fundamental characteristics of HSC:slow cavity filling,squeeze feeding and slow sleeve filling.From this,a selection principle is given based on the three related critical casting parameters:cavity filling velocity,gate size and sleeve filling velocity.Finally,two specific applications of HSC are introduced,and the future direction of HSC development is discussed.
文摘The interior of a high-pressure die-casting is of an unsatisfactory quality. Engine blocks made with this die casting process show lower specific engine performance. Pressure die-casting can hardly be heat treated for obvious reasons. PSM (Precision Sand Molds) process uses sand and organic binder to generate a mold and even allows the manufacturing of complex diesel engine blocks in aluminum alloys. Combined technologies are available for semi-permanent mold castings with cores and castings made in Precision Sand Molds with organic binders. Castings are placed into the special heat treatment furnace immediately after pouring without the operations in stand alone machinery. This patented Sand Lion 3- in-1 technology processes hot castings and carries out three (3) foundry processes simultaneously in one (1) automated machine: 1) De-coring and sand removal; 2) Thermal sand reclamation; 3) Solution heat treatment of castings. The combination of several main casting processes is reflected in significant reductions of energy consumption, of production costs, and improving the quality of the castings. Audits in foundries using the 3-in-l process showed an average reduction in production costs of more than 30%.
