Gating and Feeder Design of Aluminium Alloy (6061 T6) Casting for Circular Component
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Permanent Mold
PERMANENT MOLD CASTING PROCESSES Many variations of the permanent mold process are well-suited for mass production of high-integrity light metal castings for automotive components. This article is based on “High Integrity Permanent Mold Casting Processes: Current and Future,” a presentation at the American Foundry Society’s 6th International Conference on Permanent Mold Casting of Aluminum and Magnesium. J. L. Jorstad* JLJ Technologies Inc. This Chrysler NS cross member was cast on a tilt permanent mold machine. Richmond, Virginia However, with the incorporation of ceramic-foam filters and their ability Permanent mold casting consists of several basic to smooth melt flow (Fig. 1), opportu- processes. In this article, key characteristics of nities become available to top-pour each will be considered in terms of their impact with significantly fewer entrapped ox- on high-integrity products. ides and other quality detractors. Turbulent flow Combining filters with down-sprue GRAVITY FILLING PROCESSES and runner designs proposed by Prof. Gravity pouring, whether manual, via auto- Campbell has made it possible to pour ladles, or robotic pouring, can be susceptible to reasonably high-integrity aluminum turbulence, which has a negative effect on high- castings, perhaps most suitable for a Pintegrity castings. It is nearly impossible to have variety of less-critical automotive molten aluminum free fall more than a few cen- applications. timeters without initially exceeding a safe flow Static top-pouring has another velocity of about 0.5 to 1 m/s. Note that a free fall downside too, an ever-diminishing of less than 0.1 m will accelerate to more than 1 effective metal head as fill progresses. -
Radel® PPSU, Udel® PSU, Veradel® PESU & Acudel® Modified PPSU
Radel ® | Udel ® | Veradel ® | Acudel ® Radel® PPSU, Udel® PSU, Veradel® PESU & Acudel® modified PPSU Processing Guide SPECIALT Y POLYMERS 2 \ Sulfone Polymers Processing Guide Table of Contents Introduction ............................. 5 Part Ejection . 14 Draft . 14 Ejector pins and/or stripper plates . 14 Sulfone Polymers........................ 5 Udel® Polysulfone (PPSU) . 5 Injection Molding Equipment ............. 15 ® Veradel Polyethersulfone (PESU) . 5 Controls . 15 ® Radel Polyphenylsulfone (PPSU) . 5 Clamp . 15 ® Acudel modified PPSU . 5 Barrel Capacity . 15 Press Maintenance . 15 Resin Drying . .6 Screw Design . 15 Rheology................................ 8 Screw Tips and Check Valves . 15 Viscosity-Shear Rate ..................... 8 Nozzles . 16 Molding Process . 16 Resin Flow Characteristics . 9 Melt flow index . 9 Polymer Injection or Mold Filling . 16 Spiral flow . 9 Packing and Holding . 17 Injection Molding . .10 Cooling . 17 Molds and Mold Design .................. 10 Machine Settings ....................... 17 Tool Steels . 10 Barrel Temperatures . 17 Mold Dimensions . 10 Mold Temperature . 18 Mold Polishing . 10 Residence Time in the Barrel . 18 Mold Plating and Surface Treatments . 10 Injection Rate . 18 Tool Wear . 10 Back Pressure . 18 Mold Temperature Control . 10 Screw Speed . 18 Mold Types . 11 Shrinkage . 18 Two-plate molds . 11 Three-plate molds . 11 Regrind ............................... 19 Hot runner molds . 11 Cavity Layout . 12 Measuring Residual Stress ............... 19 Runner Systems . 12 Extrusion............................... 22 Gating . 12 Sprue gating . 12 Edge gates . 13 Predrying ............................. 22 Diaphragm gates . 13 Tunnel or submarine gates . 13 Extrusion Temperatures ................. 22 Pin gates . 13 Screw Design Recommendations . 22 Gate location . 13 Venting . 14 Sulfone Polymers Processing Guide / 3 Die Design ............................. 22 Extruded Product Types . 23 Wire . 23 Film . 23 Sheet . 23 Piping and tubing . 23 Start-Up, Shut-Down, and Purging ....... -
Cast Irons from Les Forges Du Saint- Maurice, Quebec a Metallurgical Study
Cast Irons from Les Forges du Saint- Maurice, Quebec A Metallurgical Study Henry Unglik Environment Canada Environnement Canada Parks Service Service des pares Cast Irons from Les Forges du Saint- Maurice, Quebec A Metallurgical Study Henry Unglik Studies in Archaeology Architecture and History National Historic Parks and Sites Parks Service Environment Canada ©Minister of Supply and Services Canada 1990. Available in Canada through authorized bookstore agents and other bookstores, or by mail from the Canadian Government Publishing Centre, Supply and Services Canada, Hull, Que bec, Canada Kl A 0S9. Published under the authority of the Minister of the Environment, Ottawa, 1990 Editing and design: Jean Brathwaite Production: Lucie Forget and Rod Won Parks publishes the results of its research in archaeology, architecture, and history. A list of publications is available from Research Publications, Parks Service, Environment Can ada, 1600 Liverpool Court, Ottawa, Ontario K1A 0H3. Canadian Cataloguing in Publication Data Unglik, Henry Cast irons from les Forges du Saint-Maurice, Quebec: a met allurgical study (Studies in archaeology, architecture and history, ISSN 0821-1027) Issued also in French under title: Fontes provenant des Forges du Saint-Maurice. Includes bibliographical references. ISBN 0-660-13598-1 DSS cat. no. R61-2/9-48E 1. Forges du Saint-Maurice (Quebec) — Antiquities. 2. Iron works — Quebec (Province) — Saint Maurice River Valley — History. 3. Cast-iron — Analysis. I. Canadian Parks Service. National Historic Parks and -
Additive Tooling Simplifies the Mold Build Process – 18 Conformally Cooled Sprue Bushings Reduce Cycle Time
ENGINEER / BUILD / MAINTAIN Additive Tooling Simplifies the Mold Build Process – 18 Conformally Cooled Sprue Bushings Reduce Cycle Time – 22 Best Practices for Improving Measurement Accuracy – 30 Revisiting Some Hot Runner Fundamentals – 36 FEBRUARY 2020 / VOL. 23 / NO. 2 A property of Gardner Business Media “Progressive’s Inserted Bar Locks provide perfect alignment for even our largest tools, which perform in harsh conditions.” Oswaldo Roman, Inland Die Casting Company align with the leader When producing tight tolerance parts for the automotive industry, Inland Die Casting Company knows that taking shortcuts today will lead to problems tomorrow. Progressive’s Inserted Bar Locks are designed to go the distance: • Largest, standard alignment lock in the industry • Designed for mold weights from 25,000 to 75,000 lbs • Utilizes exclusive Z-Series technology for longevity Don’t let inferior components bench your tools. Contact our Engineering team at 1-800-269-6653 to discuss how the Progressive advantage can generate profits for you. VISIT THE NEW PROCOMPS.COM FOR ENHANCED E-COMMERCE AND CAD GEOMETRY AVAILABILITY A CONTROL FOR EVERY GENERATION. For over 50 years, Hurco has been empowering machinists of every generation with cutting-edge control technology that’s easy to learn and easy to use. See which one of our 65+ models of CNC machines is right for you. Hurco.com/MyGeneration Double Column Boring Mills Horizontals 3-Axis Vertical 5-Axis Double Column Bridge Turning Centers Hurco Companies, Inc. | One Technology Way | Indianapolis, IN 46268 | 800.634.2416 | [email protected] | HURCO.com | Machines shown with options. Information may change without notice. -
Ingot Cleanliness Improvements Using Sprue Extensions Beyond the Mold Outlet
Ingot Cleanliness Improvements Using Sprue Extensions Beyond The Mold Outlet Ryan VanderMeulen ArcelorMittal Coatesville April 11, 2012 ArcelorMittal USA Locations Research Center Burns Harbor Cleveland Lackawanna Indiana Harbor Riverdale Coatesville Hennepin Conshohocken Columbus Coatings Newton Weirton Georgetown Steelton Steelmaking and processing facilities Processing facilities Research center 2 ArcelorMittal USA Plate Production Locations Indiana Harbor Cleveland Riverdale Conshohocken Burns Coatesville Harbor, Gary Steelmaking, Rolling, Heat Treating: Rolling & Heat Treating: Steelmaking: Burns Harbor, Coatesville Conshohocken, Gary Indiana Harbor, Cleveland, Riverdale 3 Plate Mills Production Focus • Burns Harbor – 160” – larger, TMCP, Q&T, precise weight – 110” – commodity to 1” – 160” @ Gary – commodity to 1.5”, Q&T • Conshohocken – 110” - commodity, thin, Q&T • Coatesville – – 140” - heavy, varied chemistries, Q&T – 206” - very wide and heavy, Q&T 4 Production Focus • East Clad, Flamecut, Conversion Most alloy and Q&T Very clean steel Very wide or heavy plate Light thickness plate Small special orders • West Control rolled Precise weight Special surface requirements Very large orders Heat Treated Commodity 5 ArcelorMittal USA Operations Coatesville Steelmaking Process Plan Electrodes Automatic Automatic Alloys Alloys Wire Feed Argon Stirring Argon Stirring Ladle Furnace Ladle Degasser Continuous Bottom Cast Slabs Poured Ingots Ladle Electric Arc Furnace 6 Ingot Casting Coatesville • Bottom pouring • Hot topping • Argon shrouding -
Hell on Wheels
MercantileEXCITINGSee section our NovemberNovemberNovember 2001 2001 2001 CowboyCowboyCowboy ChronicleChronicleChronicle(starting on PagepagePagePage 90) 111 The Cowboy Chronicle~ The Monthly Journal of the Single Action Shooting Society ® Vol. 21 No. 11 © Single Action Shooting Society, Inc. November 2008 . HELL ON WHEELS . THE SASS HIGH PLAINS REGIONAL By Captain George Baylor, SASS Life #24287 heyenne, Wyoming – The HIGHLIGHTS on pages 70-73 very name conjures up images of the Old West. chief surveyor for the Union Pacific C Wyoming is a very big state Railroad, surveyed a town site at with very few people in it. It has what would become Cheyenne, only 500,000 people in the entire Wyoming. He called it Cow Creek state, but about twice as many ante- Crossing. His friends, however, lope. A lady at Fort Laramie told me thought it would sound better as Cheyenne was nice “if you like big Cheyenne. Within days, speculators cities.” Cheyenne has 55,000 people. had bought lots for a $150 and sold A considerable amount of history them for $1500, and Hell on Wheels happened in Wyoming. For example, came over from Julesburg, Colorado— Fort Laramie was the resupply point the previous Hell on Wheels town. for travelers going west, settlers, and Soon, Cheyenne had a government, the army fighting the Indian wars. but not much law. A vigilance com- On the far west side of the state, mittee was formed and banishments, Buffalo Bill built his dream town in even lynchings, tamed the lawless- Cody, Wyoming. ness of the town to some extent. Cheyenne, in a way, really got its The railroad was always the cen- start when the South seceded from tral point of Cheyenne. -
The Lost-Wax Casting Process—Down to Basics by Eddie Bell, Founder, Santa Fe Symposium
The Lost-Wax Casting Process—Down To Basics By Eddie Bell, Founder, Santa Fe Symposium. Lost-wax casting is a ancient technique that is used today in essentially the same manner as it was first used more than 5,000 years ago. As they say, there's no messing with success. Today, of course, technology has vastly expanded the technique and produced powerful equipment that makes the process faster, easier and more productive than ever, but the basic steps remain the same. The steps below represent a simple overview and are intended to provide a beginning understanding of the casting process. Concept This is obviously where the design is initally conceived, discussed,evolved, and captured on paper—or on computer; CAD (computer aided design) software is increasingly popular among designers. You create the design you envision using the computer tool and the software creates a file that can be uploaded into a CNC mill or 3D printer. Model Build a model, either by hand-carving, guided by the paper rendering, or by uploading the CAD file into a computer controlled milling machine or a 3D printing machine. Models are made using carving wax, resin or similar material. This process can also be done in metal by a goldsmith or silversmith. Note: If a 3D printer or other rapid prototyping equipment is used, it is possible to skip the molding and wax-injection steps by using one of the resins that are specially made to go directly to the treeing process. Molding Create a mold from your master model, placing it in one of a variety of rubber or silicone materials, curing the material, then removing the model from the finished mold. -
From the on Inal Document. What Can I Write About?
DOCUMENT RESUME ED 470 655 CS 511 615 TITLE What Can I Write about? 7,000 Topics for High School Students. Second Edition, Revised and Updated. INSTITUTION National Council of Teachers of English, Urbana, IL. ISBN ISBN-0-8141-5654-1 PUB DATE 2002-00-00 NOTE 153p.; Based on the original edition by David Powell (ED 204 814). AVAILABLE FROM National Council of Teachers of English, 1111 W. Kenyon Road, Urbana, IL 61801-1096 (Stock no. 56541-1659: $17.95, members; $23.95, nonmembers). Tel: 800-369-6283 (Toll Free); Web site: http://www.ncte.org. PUB TYPE Books (010) Guides Classroom Learner (051) Guides Classroom Teacher (052) EDRS PRICE EDRS Price MF01/PC07 Plus Postage. DESCRIPTORS High Schools; *Writing (Composition); Writing Assignments; *Writing Instruction; *Writing Strategies IDENTIFIERS Genre Approach; *Writing Topics ABSTRACT Substantially updated for today's world, this second edition offers chapters on 12 different categories of writing, each of which is briefly introduced with a definition, notes on appropriate writing strategies, and suggestions for using the book to locate topics. Types of writing covered include description, comparison/contrast, process, narrative, classification/division, cause-and-effect writing, exposition, argumentation, definition, research-and-report writing, creative writing, and critical writing. Ideas in the book range from the profound to the everyday to the topical--e.g., describe a terrible beauty; write a narrative about the ultimate eccentric; classify kinds of body alterations. With hundreds of new topics, the book is intended to be a resource for teachers and students alike. (NKA) Reproductions supplied by EDRS are the best that can be made from the on inal document. -
The Influence of Using Different Types of Risers O R Chills on Shrinkage
ARCHIVES of FOUNDRY ENGINEERING ISSN (2299-2944) Volume 17 DOI: 10.1515/afe-2017-0064 Issue 2/2017 Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences 131 – 136 The Influence of Using Different Types of Risers or Chills on Shrinkage Production for Different Wall Thickness for Material EN-GJS-400-18LT I. Vasková*, M. Conev, M. Hrubovčáková Technical University of Košice, Faculty of Metallurgy, Institute of Metallurgy Letná 9, 042 00 Košice, Slovakia *Corresponding author. E-mail address: [email protected] Received 18.04.2017; accepted in revised form 22.05.2017 Abstract In modern times, there are increasing requirements for products quality in every part of manufacturing industry and in foundry industry it is not different. That is why a lot of foundries are researching, how to effectively produce castings with high quality. This article is dealing with search of the influence of using different types of risers or chills on shrinkage cavity production in ductile iron castings. Differently shaped risers were designed using the Wlodawer´s modulus method and test castings were poured with and without combination of chills. Efficiency of used risers and chills was established by the area of created shrinkage cavity using the ultrasound nondestructive method. There are introduced the production process of test castings and results of ultrasound nondestructive reflective method. The object of this work is to determine an optimal type of riser or chill for given test casting in order to not use overrated risers and thus increase the cost effectiveness of the ductile iron castings production. -
Use of Casting Simulation and Rapid Prototyping in an Undergraduate Course in Manufacturing Processes
Paper ID #15374 Use of Casting Simulation and Rapid Prototyping in an Undergraduate Course in Manufacturing Processes Dr. Mathew Schaefer, Milwaukee School of Engineering MATHEW SCHAEFER is Associate Professor of Mechanical Engineering at Milwaukee School of En- gineering. Prior to his academic work, Dr. Schaefer worked for G.E. Medical Systems and for Briggs & Stratton Corp. He earned his B.S. and M.S (Mechanical Engineering) and Ph.D (Materials Science) from Marquette University. His experiences in metallurgy, design, and failure analysis come from work in industry, projects and teaching at MSOE and projects completed as an independent consultant. He has taught courses both at university graduate/undergraduate level and has taught on-site professional development seminars. c American Society for Engineering Education, 2016 Use of Casting Simulation and Rapid Prototyping in an Undergraduate Course in Manufacturing Processes Abstract Mechanical Engineering students at Milwaukee School of Engineering (MSOE) study manufacturing processes in the junior year. Part of their study in this course is a project to create an original casting. This project encompasses several steps. First is to design the part and the associated mold system (gates & risers) for sand-casting the part. Next, students analyze performance of their mold layout through the use of SolidCast casting simulation software and make improvements to the initial mold layout. A final version of the casting design is submitted to the MSOE rapid prototyping center for fabrication of the casting patterns. The last step is to make an aluminum sand-cast part, in a small-scale foundry in MSOE’s labs. The project emphasizes the basic premise of the course; a manufactured part must be designed within the limitations and capabilities of the manufacturing process. -
Boilermaking Manual. INSTITUTION British Columbia Dept
DOCUMENT RESUME ED 246 301 CE 039 364 TITLE Boilermaking Manual. INSTITUTION British Columbia Dept. of Education, Victoria. REPORT NO ISBN-0-7718-8254-8. PUB DATE [82] NOTE 381p.; Developed in cooperation with the 1pprenticeship Training Programs Branch, Ministry of Labour. Photographs may not reproduce well. AVAILABLE FROMPublication Services Branch, Ministry of Education, 878 Viewfield Road, Victoria, BC V9A 4V1 ($10.00). PUB TYPE Guides Classroom Use - Materials (For Learner) (OW EARS PRICE MFOI Plus Postage. PC Not Available from EARS. DESCRIPTORS Apprenticeships; Blue Collar Occupations; Blueprints; *Construction (Process); Construction Materials; Drafting; Foreign Countries; Hand Tools; Industrial Personnel; *Industrial Training; Inplant Programs; Machine Tools; Mathematical Applications; *Mechanical Skills; Metal Industry; Metals; Metal Working; *On the Job Training; Postsecondary Education; Power Technology; Quality Control; Safety; *Sheet Metal Work; Skilled Occupations; Skilled Workers; Trade and Industrial Education; Trainees; Welding IDENTIFIERS *Boilermakers; *Boilers; British Columbia ABSTRACT This manual is intended (I) to provide an information resource to supplement the formal training program for boilermaker apprentices; (2) to assist the journeyworker to build on present knowledge to increase expertise and qualify for formal accreditation in the boilermaking trade; and (3) to serve as an on-the-job reference with sound, up-to-date guidelines for all aspects of the trade. The manual is organized into 13 chapters that cover the following topics: safety; boilermaker tools; mathematics; material, blueprint reading and sketching; layout; boilershop fabrication; rigging and erection; welding; quality control and inspection; boilers; dust collection systems; tanks and stacks; and hydro-electric power development. Each chapter contains an introduction and information about the topic, illustrated with charts, line drawings, and photographs. -
Riser Feeding Evaluation Method for Metal Castings Using
Riser Feeding Evaluation Method for Metal Castings Using Numerical Analysis DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Nadiah Ahmad Graduate Program in Industrial and Systems Engineering The Ohio State University 2015 Dissertation Committee: Dr. Jerald Brevick, Advisor Dr. Theodore Allen Dr. Jose Castro i Copyright by Nadiah Ahmad 2015 ii Abstract One of the design aspects that continues to create a challenge for casting designers is the optimum design of casting feeders (risers). As liquid metal solidifies, the metal shrinks and forms cavities inside the casting. In order to avoid shrinkage cavities, risers are added to the casting shape to supply additional molten metal when shrinkage occurs during solidification. The shrinkage cavities in the casting are compensated by controlling the cooling rate to promote directional solidification. This control can be achieved by designing the casting such that the cooling begins at the sections that are farthest away from the risers and ends at the risers. Therefore, the risers will solidify last and feed the casting with the molten metal. As a result, the shrinkage cavities formed during solidification are in the risers which are later removed from the casting. Since casting designers have to usually go through iterative processes of validating the casting designs which are very costly due to expensive simulation processes or manual trials and errors on actual casting processes, this study investigates more efficient methods that will help casting designers utilize their casting experiences systematically to develop good initial casting designs.