Journal of Casting & Materials Engineering
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ISSN 2543-9901
Issue Date
2021
Volume
Vol. 5
Number
No. 1
Description
Journal Volume
Journal of Casting & Materials Engineering
Vol. 5 (2021)
Projects
Pages
Articles
Optimization of a gating system by means of simulation software to eliminate cold shut defects in casting
(AGH University of Science and Technology Press, 2021) Šabík, Vladimír; Futáš, Peter; Pribulová, Alena; Delimanová, Petra
The current trend in foundries is to achieve the production of high quality and competitive cast components. The innovation and optimization of current processes is a necessary element to achieve this goal. With the help of numerical simulations, it is possible to replace financially demanding and time-consuming experiments in real conditions with simulations that can reliably represent foundry process using computer technology. By a detailed analysis of the simulation results, we can predict various risks that could negatively affect the production process. This article monitors the influence of changes in the design of the gating system on the surface quality of a clutch wheel casting made of ductile iron, in the production of which two models of the gating system for casting were constructed in CAD software. Verification of gating systems was performed using the simulation software NovaFlow & Solid. The aim of the design change of the gating system is to reduce the amount of liquid metal used per casting, which can have a significant economic impact on industrial production. For this purpose, several simulations of the gating system of the casting were performed, while 2 which are the most representative for the mentioned problem were selected for the needs of the article. The main task of the simulation was to set the cellular network and conditions as close as possible to the reality of casting and the subsequent design and modification of the gating system.
Optimization of blast furnace throughput based on hearth refractory lining and shell thickness
(AGH University of Science and Technology Press, 2021) Ossia, Chinwuba Victor; Uzoma, Shedrack Mathew
Computational analyses were performed to optimize the furnace throughput, steel shell and lining thickness of a blast furnace. The computations were done for measured parameters within the hearth region as this is the vital zone of the furnace with high temperature fluctuations, molten iron, and slag production. The lining materials were namely 62% high alumina (A), carbon composite (B), silicon carbide (C) and graphite bricks (D) with thermal conductivities 2, 12, 120 and 135 W/(m$\cdot$K), respectively. It was observed that by varying the refractory lining thickness from 0.2-0.35 m, and furnace inside temperatures from 1873-2073 K, certain optimal conditions could be specified for the furnace under consideration. Silicon carbide and graphite brick linings which have higher thermal conductivities, melting points, good chemical and mechanical wear resistance were observed to be the best hearth lining materials. Due to the high thermal conductivities of these two materials, the hot face temperature levels of the lining materials would be lowered. Amongst the four lining materials employed, silicon carbide and graphite bricks when used with lining cooling systems could optimize the blast furnace for better performance, production, and longer campaigns.