PermanentMoldOptimizationCaseStudy-RiserSizeandLocation课程.pptVIP

Modeling a permanent mold casting for process optimization F. Chiesa, Collège de Trois-Rivières, Trois-Rivières, Québec S. Guillet, Lycée Technique Guimard, Lyon, France L.E. Smiley, Finite Solutions Inc, Cincinnati, Ohio Outline of the presentation The treatment of the mold metal interface when modeling solidification The casting under study, casting conditions and model calibration. Correlation between metallurgical quality and results of modeling Principles of riser optimization Applying riser optimization to the casting under study Conclusion The finished casting The rough casting The mold The cycling Treatment of mold-casting interface Mold-casting interface: step funtion Location of 4 thermocouples Predicted temperatures in mold and casting Radiograph of casting (cycle 16) Metallographic structure 21μm 19 μm 0.13% Progression of c.f.s. frontand material density 21 μm 0.22% 21 μm  0.13% Steps Required for Optimization Design Variables Constraints An Objective Function Example 2 Single Riser: Size and Position Optimization (Starting with Original Riser Size) Design Variable: Riser Position Lower-X Limit of Riser Position Upper-X Limit of Riser Position Constraint Material Density 0.994 Objective Function Maximize Yield Results After 8 Simulations Yield (%) Material Density Riser Size Position Time to Critical Fraction Solid Point Material Density (0.995) Final Results: Optimum Size and Location Conclusions Original riser location is about optimal Riser can be reduced to 79% of original size and still achieve target Material Density American Foundry Society . 106th Casting Congress Cast Expo May 4-7, 2002--Kansas City MO, USA Automatic Process Design Optimization Using Multi-Variable Response Surface Technique Why Automatic Process Optimization ? Foundry Engineer Initial Design Process Simulation System Foundry Engineer Revised Design Simulation Results Decide What to Change Acc