In current casting factories, tilting type automatic pouring machines are often used to pour the molten metal into the mold, with the operator relying on experience, perception and repeated testing to manually determine the pouring velocity. However, seeking an optimum multistep pouring velocity through trial and error results in an enormous number of combinations and is very difficult. For thi...

Many casting defects, which cannot be eliminated by changes to tooling and process parameters, can be attributed to poor design of the part with respect to manufacturability. One such common defect is shrinkage porosity occurring at casting junctions. We present a generic classification of 3D casting junctions in terms of the number, thickness and cross-section of converging elements (walls), a...

Optimum casting designs are unreliable without consideration of the statistical and physical uncertainties in the casting process. In the present research, casting simulation is integrated with a general purpose reliability-based design optimization (RBDO) software tool previously developed at the University of Iowa. The RBDO methodology considers uncertainties in both the input variables as we...

The fuzzy neuron hybrid control method is proposed for mold level control of the continuous steel casting in this paper. The dynamic characteristics of the continuous steel casting process is described. To the plant with big uncertainties and grave nonlinearities, the fuzzy neuron hybrid control system is set up and the new model-free controller is designed. In this control system, the fuzzy ne...

ÐWe present an efficient and robust ray-casting algorithm for directly rendering a curvilinear volume of arbitrarily-shaped cells. By projecting cell-faces onto the image plane, we have effectively addressed three critical steps of the ray-casting process, namely finding the entry cell-faces for a ray, traversing along the ray from one cell to another, and reconstructing data values at the ray/...

Abstract: The horizontal continuous casting process has received a significant attention for near net shape casting of non ferrous metals and alloys. Numerical Simulation has been widely used for process design and optimization of continuous casting process. In the present study, a 3-dimensional heat flow model was developed to simulate the heat transfer and solidification in a horizontal b...

We discuss selected aspects of a new parallel three-dimensional (3-D) computational tool for the unstructured mesh simulation of Los Alamos National Laboratory (LANL) casting processes. This tool, known as Telluride, draws upon on robust, high resolution finite volume solutions of metal alloy mass, momentum, and enthalpy conservation equations to model the filling, cooling, and solidification o...

Article history: Received: 13.04.2015. Received in revised form: 13.07.2015. Accepted: 15.07.2015. In this article, both chemical composition and structure of a high chromium iron hammer head were designed and analyzed respectively. Also, the casting process was investigated and optimized through numerical simulation using commercial software View Cast. On the basis of numerical simulation and ...

A hot tear indicator based on the physics of solidification and deformation is presented. This indicator is derived using available data from computer simulation of solidification and solid deformation. Hot tears form when the mushy zone is starved of liquid feeding and deformed in tension. The unfed tensile deformation causes a small additional porosity. A physical model based on a mass balanc...