Eventos Anais de eventos
COBEM 2021
26th International Congress of Mechanical Engineering
COB-2021-1055 COMPUTATIONAL SIMULATION FOR EVALUATION AND OPTIMIZATION OF CASTING PARAMETERS FOR ALUMINUM-SILICON ALLOYS
Submission Author:
Carlos Costa de Carvalho , RN
Co-Authors:
Carlos Costa de Carvalho, Diego Diniz, Jackson Simoes
Presenter: Carlos Costa de Carvalho
doi://10.26678/ABCM.COBEM2021.COB2021-1055
Abstract
The casting process is employed in various industry sectors, it moves several companies, and generates thousands of jobs. In the recent decades, the computer simulation made it possible to increase productivity and resource savings through the elimination of empirical methods (trial and error) in gating and feeding design, predicting defects before the prototype manufacturing process. In the other hand, the number of studies involving casting simulation is still considered low, as well as the qualification necessary to develop related projects; the reason is that this technology is still considered recent and little explored. This work aims to present a computational modeling study focusing on the optimization of casting process through the analysis of the following parameters: heat transfer coefficient (HTC), mold temperature, pouring temperature, and pouring time. The mold was designed in the software Autodesk Inventor 2019, and then exported to the ESI ProCAST 2019; the simulations were conducted considering the gravity sand casting process for the AlSi7Mg aluminum-silicon alloy. Thus, 16 simulations were carried out in which the casting quality was evaluated through three metrics: maximum local porosity, average porosity and hot spots. The results presented the possibility of predicting the behavior of phenomena present in the casting process, in which the HTC parameter and the pouring time had less significant influence on the casting quality. Finally, it was possible to optimize and quantify the study variables in a gating design of a flywheel; it was verified that the low levels of casting defects ensured the component quality.
Keywords
Porosity, casting, Simulation, Optimization, Alloys
