Simulation

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Simulation Prototyping of a Sand-Cast
Component MY4130 Final Project Steve Tarnowski
Anna Keranen Fall Semester, 2004 Michigan
Technological University December 9, 2004
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Table of Contents

• Introduction
• Objectives
• Procedure
• - Casting design
• - Magmasoft simulation
• - Prototype sand casting
• IV. Results
• - Initial gating system
• - Gating system 2 with risers
• - Gating system 3
• V. Conclusions

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Introduction

• Steering arm component (heavy military truck)
• Commercially squeeze-cast
• D357-T6 aluminum
• Machined after heat-treatment

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Project Objectives

• 1.) Prototype the part as an A354 aluminum sand
  casting
• 2.) Design an appropriate gating and risering
  system
• 3.) Perform casting simulations with Magmasoft
• 4.) Correlate simulation results with prototype
  casting

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Procedure

• 1.) Design an initial gating system
• 2.) Magmasoft simulation of initial gating system
• 3.) Create a sand mold and gravity-cast a
  prototype part
• 4.) Modify gating system design risers, if
  necessary
• 5.) Validate risering system with Magmasoft

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Initial gating system

• Horizontal parting line
• Sprue

Runners
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Gating 1 filling simulation (1.5 sec)
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Gating 1 filling simulation (3 sec)
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Gating 1 filling simulation (6 sec)
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Gating 1 filling simulation (12 sec)
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Gating 1 solidification (2 min, 56 sec)
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Gating 1 solidification (7 min, 56 sec)
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Gating 1 Simulated Cooling Curve
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Gating 1 Predicted porosity defects
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Gating system 2 Added a riser
Riser was calculated with a modulus (1.1) x
(casting modulus)
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Gating 2 filling simulation (1.5 sec)
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Gating 2 filling simulation (6 sec)
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Gating 2 filling simulation (15 sec)
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Gating 2 solidification (5 minutes)
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Gating 2 solidification (12 minutes)
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Gating 2 Porosity prediction
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Gating system 3
Sprue at part mass center Risers on the ends
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Gating 3 filling simulation (3 sec)
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Gating 3 filling simulation (10.5 sec)
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Gating 3 Solidification (5 min, 41 sec)
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Gating 3 Solidification (12 min, 38 sec)
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Gating 3 Porosity prediction
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Sand mold gravity casting
Gating system 1 was prototyped for correlation
with Magmasoft simulation Oil-bonded sand
Pour temperature of 825 C and pour time of 15
seconds Poured approximately 20 lb of A354
aluminum Existing part was used as the pattern
to create the mold Used a horizontal parting
line
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Sand cast steering arm
lots of flash
external macro shrinkage
Surface porosity is evident, especially at
corners
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Sand cast steering arm
Shrinkage lt 1 on overall dimensions Overall
part quality is good, except for excess flash
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Conclusions
Magmasoft prediction was reliable External
macro shrinkage was accurately predicted Gating
2 and 3 corrected the macro shrinkage Gating
3 further improved the casting quality at the
ends of the part and does not require runners.
Gating 2 casting yield is about 71 Gating 3
casting yield is about 77, thus it is the more
economical option for production
Squeeze-casting is still a better way to produce
this part because of better casting quality,
yield and cycle times.
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Future Development Work
Microstructural porosity analysis Hardness
testing Tensile testing Casting trials of
improved gating systems Ultrasonic or X-ray
inspection