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An energy consumption prediction approach of die casting machines driven by product parameters

《机械工程前沿（英文）》 2021年第16卷第4期页码 868-886 doi: 10.1007/s11465-021-0656-0

摘要： Die casting machines, which are the core equipment of the machinery manufacturing industry, consume great amounts of energy. The energy consumption prediction of die casting machines can support energy consumption quota, process parameter energy-saving optimization, energy-saving design, and energy efficiency evaluation; thus, it is of great significance for Industry 4.0 and green manufacturing. Nevertheless, due to the uncertainty and complexity of the energy consumption in die casting machines, there is still a lack of an approach for energy consumption prediction that can provide support for process parameter optimization and product design taking energy efficiency into consideration. To fill this gap, this paper proposes an energy consumption prediction approach for die casting machines driven by product parameters. Firstly, the system boundary of energy consumption prediction is defined, and subsequently, based on the energy consumption characteristics analysis, a theoretical energy consumption model is established. Consequently, a systematic energy consumption prediction approach for die casting machines, involving product, die, equipment, and process parameters, is proposed. Finally, the feasibility and reliability of the proposed energy consumption prediction approach are verified with the help of three die casting machines and six types of products. The results show that the prediction accuracy of production time and energy consumption reached 91.64% and 85.55%, respectively. Overall, the proposed approach can be used for the energy consumption prediction of different die casting machines with different products.

关键词： die casting machine energy consumption prediction product parameters

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Ultrasonic measurement of tie-bar stress for die-casting machine

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0663-1

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Determining casting defects in near-net shape casting aluminum parts by computed tomography

Jiehua LI, Bernd OBERDORFER, Daniel HABE, Peter SCHUMACHER

《机械工程前沿（英文）》 2018年第13卷第1期页码 48-52 doi: 10.1007/s11465-018-0493-y

摘要：

Three types of near-net shape casting aluminum parts were investigated by computed tomography to determine casting defects and evaluate quality. The first, second, and third parts were produced by low-pressure die casting (Al-12Si-0.8Cu-0.5Fe-0.9Mg-0.7Ni-0.2Zn alloy), die casting (A356, Al-7Si-0.3Mg), and semi-solid casting (A356, Al-7Si-0.3Mg), respectively. Unlike die casting (second part), low-pressure die casting (first part) significantly reduced the formation of casting defects (i.e., porosity) due to its smooth filling and solidification under pressure. No significant casting defect was observed in the third part, and this absence of defects indicates that semi-solid casting could produce high-quality near-net shape casting aluminum parts. Moreover, casting defects were mostly distributed along the eutectic grain boundaries. This finding reveals that refinement of eutectic grains is necessary to optimize the distribution of casting defects and reduce their size. This investigation demonstrated that computed tomography is an efficient method to determine casting defects in near-net shape casting aluminum parts.

关键词： near-net shape casting aluminum parts casting defects low pressure die casting die casting semi-solid casting computed tomography

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Interfacial heat transfer coefficient between metal and die during high pressure die casting process

GUO Zhipeng, XIONG Shoumei, CHO SangHyun, CHOI JeongKil

《机械工程前沿（英文）》 2007年第2卷第3期页码 283-287 doi: 10.1007/s11465-007-0049-z

摘要： The present work focused on the determination of the interfacial heat transfer coefficient (IHTC) between metal and die during the high pressure die casting (HPDC) process. Experiments were carried out on an aluminum alloy, ADC12Z, using step shape casting so-called because of its shape. The IHTC was successfully determined by solving one of the inverse heat problems using the nonlinear estimation method first used by Beck. The calculation results indicated that the IHTC immediately increased after liquid metal was brought into the cavity by the plunger and decreased as the solidification process of the liquid metal proceeded. The liquid metal eventually solidified completely, a condition when the IHTC tended to be stable. Casting thickness played an important role in affecting the IHTC between the metal and die not only in terms of its value but also in terms of its change tendency. Also, under the test conditions, different change tendencies of the metal solid fraction were found between castings with different thicknesses and the die.

关键词： so-called calculation inverse interfacial aluminum

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连续铸钢前沿技术的工程化

干勇

《中国工程科学》 2002年第4卷第9期页码 12-18

摘要：

论述了具有我国自主知识产权的高效连铸和薄板坯连铸工程化关键技术的特点；介绍了连续铸钢领域轻压下、液压非正弦振动、电磁连铸等前沿技术的开发现状；阐述了传统连铸技术超高效率、高品质化及近终形连铸、电磁连铸开发的研发方向。

关键词：连续铸钢高效连铸薄板坯连铸轻压下电磁连铸

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Novel casting processes for single-crystal turbine blades of superalloys

Dexin MA

《机械工程前沿（英文）》 2018年第13卷第1期页码 3-16 doi: 10.1007/s11465-018-0475-0

摘要：

This paper presents a brief review of the current casting techniques for single-crystal (SC) blades, as well as an analysis of the solidification process in complex turbine blades. A series of novel casting methods based on the Bridgman process were presented to illustrate the development in the production of SC blades from superalloys. The grain continuator and the heat conductor techniques were developed to remove geometry-related grain defects. In these techniques, the heat barrier that hinders lateral SC growth from the blade airfoil into the extremities of the platform is minimized. The parallel heating and cooling system was developed to achieve symmetric thermal conditions for SC solidification in blade clusters, thus considerably decreasing the negative shadow effect and its related defects in the current Bridgman process. The dipping and heaving technique, in which thin-shell molds are utilized, was developed to enable the establishment of a high temperature gradient for SC growth and the freckle-free solidification of superalloy castings. Moreover, by applying the targeted cooling and heating technique, a novel concept for the three-dimensional and precise control of SC growth, a proper thermal arrangement may be dynamically established for the microscopic control of SC growth in the critical areas of large industrial gas turbine blades.

关键词： superalloy investment casting Bridgman process directional solidification single crystal turbine blade

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Novel technologies for the lost foam casting process

Wenming JIANG, Zitian FAN

《机械工程前沿（英文）》 2018年第13卷第1期页码 37-47 doi: 10.1007/s11465-018-0473-2

摘要：

Lost foam casting (LFC) is a green precision casting process categorized as a near net forming technology. Yet, despite its popularity, it still suffers from some technological problems, such as poor filling ability of the castings, coarse and non-dense microstructure, low mechanical properties for the Al and Mg LFC processes, and defective carburization for the low carbon steel LFC process. These drawbacks restrict the development and widespread application of the LFC process. To solve these problems, the present study developed several novel LFC technologies, namely, LFC technologies under vacuum and low pressure, vibration solidification, and pressure solidification conditions; expendable shell casting techno- logy; and preparation technology of bimetallic castings based on the LFC process. The results showed that the LFC under vacuum and low pressure evidently improved the filling ability and solved the oxidization problem of the alloys, which is suitable for producing complex and thin-wall castings. The vibration and pressure solidifications increased the compactness of the castings and refined the microstructure, significantly improving the mechanical properties of the castings. The expendable shell casting technology could solve the pore, carburization, and inclusion defects of the traditional LFC method, obtaining castings with acceptable surface quality. Moreover, the Al/Mg and Al/Al bimetallic castings with acceptable metallurgical bonding were successfully fabricated using the LFC process. These proposed novel LFC technologies can solve the current technological issues and promote the technological progress of the LFC process.

关键词： LFC under vacuum and low pressure vibration solidification pressure solidification expendable shell casting bimetallic castings

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Hybrid forming mechanism of patternless casting and laser cladding

Zhongde SHAN, Fuzhen SUN, Yang LIU

《机械工程前沿（英文）》 2019年第14卷第4期页码 393-401 doi: 10.1007/s11465-019-0550-1

摘要： In accordance with the requirement of manufacturing dies quickly and economically, a hybrid forming method of stamping dies for automobile panels is proposed. The method combines digital patternless casting and high-power laser cladding. An experimental study is conducted on the hybrid forming process and its trial production and application in the manufacturing of stamping dies for typical panels. Results prove that the laser cladding layer exceeds HRC60 (Rockwell hardness) and thus meets the production efficiency requirement of automobile dies. The rate of defects is well controlled. Compared with traditional technology, this technology has remarkable advantages and advancement.

关键词： patternless casting laser cladding hybrid forming rapid tooling

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Numerical investigation of the influence of casting techniques on fiber orientation distribution in ECC

Chung Nguyen VAN; Hai TRAN THANH; Thuc Nhu NGUYEN; Jianchun LI

《结构与土木工程前沿（英文）》 2022年第16卷第11期页码 1424-1435 doi: 10.1007/s11709-022-0870-9

摘要： Engineered cementitious composites (ECC), also known as bendable concrete, were developed based on engineering the interactions between fibers and cementitious matrix. The orientation of fibers, in this regard, is one of the major factors influencing the ductile behavior of this material. In this study, fiber orientation distributions in ECC beams influenced by different casting techniques are evaluated via numerical modeling of the casting process. Two casting directions and two casting positions of the funnel outlet with beam specimens are modeled using a particle-based smoothed particle hydrodynamics (SPH) method. In this SPH approach, fresh mortar and fiber are discretized by separated mortar and fiber particles, which smoothly interact in the computational domain of SPH. The movement of fiber particles is monitored during the casting simulation. Then, the fiber orientations at different sections of specimens are determined after the fresh ECC stops flowing in the formwork. The simulation results show a significant impact of the casting direction on fiber orientation distributions along the longitudinal wall of beams, which eventually influence the flexural strength of beams. In addition, casting positions show negligible influences on the orientation distribution of fibers in the short ECC beam, except under the pouring position.

关键词： ECC fiber orientation distribution casting direction casting position

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Thermal deflection analysis of the solidified shell in continuous casting of slab

LIU Hongzhao, WANG Zhongmin

《机械工程前沿（英文）》 2007年第2卷第2期页码 175-179 doi: 10.1007/s11465-007-0029-3

摘要： The thermal deformation problem in the continuous casting of a slab subjected to thermal loading because of the temperature gradient along the solidified shell thickness is investigated. On the basis of the reciprocal theorem of work or Betti-Maxwell s reciprocal theorem and the superposition principle, the deflection expressions for a rectangular plate with the two opposite edges simply supported, and the other two opposite edges clamped under the action of the uniformly distributed load and nonuniform temperature field are derived respectively. The meaning of each term in the deflection expression obtained by the reciprocal theorem of work is explained. Then the practical example is given to calculate the thermal deformation and the bulging deformation of the solidified shell under three tension speeds. This research is useful for analyzing the bulging deformation in the continuous casting of a slab under the static pressure of the molten steel and the thermal loading because of the temperature gradient along the solidified shell thickness.

关键词： s reciprocal loading deflection expression reciprocal opposite

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Establishment of the Comprehensive Evaluation System of Cold Stamping Die Quality

LU Xiao-chun, GUO Sheng, RUAN Feng

《机械工程前沿（英文）》 2006年第1卷第1期页码 80-84 doi: 10.1007/s11465-005-0021-8

摘要：

A comprehensive evaluation system of die quality, a multiplayer hierarchical amendment index system according to the characteristics of cold stamping die production, an evaluation standard referring to the technique and design rules of dies, and a scientific evaluation by using the multiplayer hierarchical and the fuzzy comprehensive evaluation methods are presented in this paper. The applications show that the system can be used to evaluate the die quality objectively, fairly, and reasonably.

关键词： scientific evaluation stamping multiplayer hierarchical technique evaluation standard

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铸件凝固过程的宏观及微观模拟仿真研究进展

柳百成

《中国工程科学》 2000年第2卷第9期页码 29-37

摘要：

面向市场经济，迎接全球化竞争的挑战，为国民经济的发展作贡献，就要十分重视制造业特别是铸造行业的发展。但是，我国铸造行业与国外相比有很大差距，它制约着国民经济的发展。世界各国在铸造成形加工技术的发展趋势方面，认识是一致的，即：一是大型工程中特大型铸件的关键铸造技术；二是向精确成形技术方向发展；三是用计算机模拟仿真逐步代替传统的经验性研究方法。铸造过程计算机模拟仿真是改造传统铸造产业的必由之路，是当今世界各国专家学者关注的热点。铸造充型凝固过程的数值模拟可以帮助工程技术.人员优化工艺设计，缩短试制周期、降低生产成本、确保铸件质量，已成为铸造领域最热门的研究课题之一。目前，凝固过程的流场、温度场数值模拟及缩孔缩松预测已应用于实际生产，应力分析、微观组织模拟等方面的基础研究及实用化进程都取得了很大进展。

关键词：铸造凝固过程模拟仿真净形铸造

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Digital high-efficiency print forming method and device for multi-material casting molds

Zhongde SHAN, Zhi GUO, Dong DU, Feng LIU, Wenjiang LI

《机械工程前沿（英文）》 2020年第15卷第2期页码 328-337 doi: 10.1007/s11465-019-0574-6

摘要： Sand mold 3D printing technology based on the principle of droplet ejection has undergone rapid development in recent years and has elicited increasing attention from engineers and technicians. However, current sand mold 3D printing technology exhibits several problems, such as single-material printing molds, low manufacturing efficiency, and necessary post-process drying and heating for the manufacture of sand molds. This study proposes a novel high-efficiency print forming method and device for multi-material casting molds. The proposed method is specifically related to the integrated forming of two-way coating and printing and the short-flow manufacture of roller compaction and layered heating. These processes can realize the high-efficiency print forming of high-performance sand molds. Experimental results demonstrate that the efficiency of sand mold fabrication can be increased by 200% using the proposed two-way coating and printing method. The integrated forming method for layered heating and roller compaction presented in this study effectively shortens the manufacturing process for 3D-printed sand molds, increases sand mold strength by 63.8%, and reduces resin usage by approximately 30%. The manufacture of multi-material casting molds is demonstrated on typical wheeled cast-iron parts. This research provides theoretical guidance for the engineering application of sand mold 3D printing.

关键词： multi-material casting mold 3D printing efficient print forming method

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Multiobjective image recognition algorithm in the fully automatic die bonder

JIANG Kai, CHEN Hai-xia, YUAN Sen-miao

《机械工程前沿（英文）》 2006年第1卷第3期页码 313-316 doi: 10.1007/s11465-006-0026-y

摘要： It is a very important task to automatically fix the number of die in the image recognition system of a fully automatic die bonder. A multiobjective image recognition algorithm based on clustering Genetic Algorithm (GA), is proposed in this paper. In the evolutionary process of GA, a clustering method is provided that utilizes information from the template and the fitness landscape of the current population. The whole population is grouped into different niches by the clustering method. Experimental results demonstrated that the number of target images could be determined by the algorithm automatically, and multiple targets could be recognized at a time. As a result, time consumed by one image recognition is shortened, the performance of the image recognition system is improved, and the atomization of the system is fulfilled.

关键词： clustering different recognition algorithm Algorithm multiobjective

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An automated arc spray tooling system for rapid die-making of large-sized automobile body panels

HE Zhong-yun, LU Bing-heng, WANG Yi-qing, HONG Jun, TANG Yi-ping

《机械工程前沿（英文）》 2006年第1卷第2期页码 209-214 doi: 10.1007/s11465-006-0012-4

摘要： A creative robot wrist consisting of link mechanisms and a novel robot motion control method based on the cross-sectional vector contours of an STL-formatted model was proposed. By using the wrist and the control method, an industrial robot with five degrees of freedom for rapid tooling using metal arc spraying and electric brush plating techniques was developed. The wrist of the robot including a specially designed link mechanism can maintain the position of the spraying point on the surface of the master pattern whatever the orientation of the gun. Therefore, the kinematic nonlinear coupling between the position mechanism and orientation mechanism in a traditional robot can be avoided. The only input of the control system is the STL-formatted 3D CAD model of the pattern. Without the need of any manual programming, the metal arc spraying and brush plating (if necessary) processes can be performed automatically and efficiently after receiving the 3D CAD data of the pattern. Using this robot system in new car development and trial production, the cost and lead-time can be reduced substantially as compared with the conventional tool making method.

关键词： industrial position mechanism orientation surface cross-sectional