The simulation field became essential in designing or developing new casting products and in improving manufacturing processes within limited time, because it can help us to simulate the nature of processing, so that ...The simulation field became essential in designing or developing new casting products and in improving manufacturing processes within limited time, because it can help us to simulate the nature of processing, so that developers can make ideal casting designs. To take the prior occupation at commercial simulation market, so many development groups in the world are doing their every effort. They already reported successful stories in manufacturing fields by developing and providing the high performance simulation technologies for multipurpose. But they all run at powerful desk-side computers by well-trained experts mainly, so that it is hard to diffuse the scientific designing concept to newcomers in casting field. To overcome upcoming problems in scientific casting designs, we utilized information technologies and full-matured hardware backbones to spread out the effective and scientific casting design mind, and they all were integrated into Simulation Portal on the web. It professes scientific casting design on the NET including ubiquitous access way represented by ＂Anyone, Anytime, Anywhere＂ concept for casting designs.展开更多
Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative...Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative effects of shrinkage cavity defects.In this paper,process of Al alloy wheel impact test was computationally analyzed for both the wheel models with and without shrinkage cavity defects.Based on shrinkage cavity data obtained from industrial CT (Computerized Tomography),the shrinkage cavity defects were modeled with SSM (Shape Simplification Method),which reconstructs shrinkage cavity defects to hollow spheroid primitives.After the impact simulation was conducted,the results show that under impact test condition,the wheel considering shrinkage cavity defects may fracture while the sound-assumed wheel may not.展开更多
Up to now,so much casting analysis software has been continuing to develop the new access way to real casting processes. Those include the melt flow analysis,heat transfer analysis for solidification calculation,mecha...Up to now,so much casting analysis software has been continuing to develop the new access way to real casting processes. Those include the melt flow analysis,heat transfer analysis for solidification calculation,mechanical property predictions and microstructure predictions. These trials were successful to obtain the ideal results comparing with real situations,so that CAE technologies became inevitable to design or develop new casting processes. But for manufacturing fields,CAE technologies are not so frequently being used because of their difficulties in using the software or insufficient computing performances. To introduce CAE technologies to manufacturing field,the high performance analysis is essential to shorten the gap between product designing time and prototyping time. The software code optimization can be helpful,but it is not enough,because the codes developed by software experts are already optimized enough. As an alternative proposal for high performance computations,the parallel computation technologies are eagerly being applied to CAE technologies to make the analysis time shorter. In this research,SMP (Shared Memory Processing) and MPI (Message Passing Interface) (1) methods for parallelization were applied to commercial software "Z-Cast" to calculate the casting processes. In the code parallelizing processes,the network stabilization,core optimization were also carried out under Microsoft Windows platform and their performances and results were compared with those of normal linear analysis codes.展开更多
Numerical simulations were used to optimize the casting design and conditions for large cast iron castings for marine engines, Simulations of the mold filling and solidification sequences were used to analyze the prob...Numerical simulations were used to optimize the casting design and conditions for large cast iron castings for marine engines, Simulations of the mold filling and solidification sequences were used to analyze the problems of previous casting conditions with marked improvements for large cylinder liner parts, The amount and positions of chills were optimized to improve the mechanical properties and to minimize the shrinkage and micro porosity in the castings. Ultra sonic testing, penetration testing, and mechanical property testing show no defects in the castings with the productivity significantly increased.展开更多
文摘The simulation field became essential in designing or developing new casting products and in improving manufacturing processes within limited time, because it can help us to simulate the nature of processing, so that developers can make ideal casting designs. To take the prior occupation at commercial simulation market, so many development groups in the world are doing their every effort. They already reported successful stories in manufacturing fields by developing and providing the high performance simulation technologies for multipurpose. But they all run at powerful desk-side computers by well-trained experts mainly, so that it is hard to diffuse the scientific designing concept to newcomers in casting field. To overcome upcoming problems in scientific casting designs, we utilized information technologies and full-matured hardware backbones to spread out the effective and scientific casting design mind, and they all were integrated into Simulation Portal on the web. It professes scientific casting design on the NET including ubiquitous access way represented by ＂Anyone, Anytime, Anywhere＂ concept for casting designs.
文摘Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative effects of shrinkage cavity defects.In this paper,process of Al alloy wheel impact test was computationally analyzed for both the wheel models with and without shrinkage cavity defects.Based on shrinkage cavity data obtained from industrial CT (Computerized Tomography),the shrinkage cavity defects were modeled with SSM (Shape Simplification Method),which reconstructs shrinkage cavity defects to hollow spheroid primitives.After the impact simulation was conducted,the results show that under impact test condition,the wheel considering shrinkage cavity defects may fracture while the sound-assumed wheel may not.
文摘Up to now,so much casting analysis software has been continuing to develop the new access way to real casting processes. Those include the melt flow analysis,heat transfer analysis for solidification calculation,mechanical property predictions and microstructure predictions. These trials were successful to obtain the ideal results comparing with real situations,so that CAE technologies became inevitable to design or develop new casting processes. But for manufacturing fields,CAE technologies are not so frequently being used because of their difficulties in using the software or insufficient computing performances. To introduce CAE technologies to manufacturing field,the high performance analysis is essential to shorten the gap between product designing time and prototyping time. The software code optimization can be helpful,but it is not enough,because the codes developed by software experts are already optimized enough. As an alternative proposal for high performance computations,the parallel computation technologies are eagerly being applied to CAE technologies to make the analysis time shorter. In this research,SMP (Shared Memory Processing) and MPI (Message Passing Interface) (1) methods for parallelization were applied to commercial software "Z-Cast" to calculate the casting processes. In the code parallelizing processes,the network stabilization,core optimization were also carried out under Microsoft Windows platform and their performances and results were compared with those of normal linear analysis codes.
文摘Numerical simulations were used to optimize the casting design and conditions for large cast iron castings for marine engines, Simulations of the mold filling and solidification sequences were used to analyze the problems of previous casting conditions with marked improvements for large cylinder liner parts, The amount and positions of chills were optimized to improve the mechanical properties and to minimize the shrinkage and micro porosity in the castings. Ultra sonic testing, penetration testing, and mechanical property testing show no defects in the castings with the productivity significantly increased.
