Search results for: Twin roll casting

Authors: H. Harada, S. Nishida, T. Nagumo, M. Endo, H. Watari

Abstract:

This study was aimed for investigating of manufacturing high aluminum content Mg alloys using a horizontal twin roll caster. Recently, weight saving has been key issues for lighter transport equipments as well as electronic component parts. As alternative materials to aluminum alloys, developing magnesium alloy with higher strength has been expected. Normally high Aluminum content Mg alloy has poor ductility and is difficult to be rolled because of its high strength. However, twin roll casting process is suitable for manufacturing wrought Mg alloys because materials can be cast directly from molten metal. In this study, manufacturing of high aluminum content magnesium alloy sheet using the roll casting process has been carried out. Effects of manufacturing parameter, such as roll velocity, pouring temperature and roll gap, on casting was investigated. A microscopic observation of the crystals of cross section of as cast strip as well as rolled strip was conducted.

Keywords: AZ91, AZ111, AZ121, Magnesium alloys, Twin roll casting

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Authors: H. B. Tibar, Z. Y. Jiang

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In this study, the influence of rolling process parameters such as the work roll cross angle and work roll shifting value on the strip shape and profile of aluminum have been investigated under dry conditions at a speed ratio of 1.3 using Hille 100 experimental mill. The strip profile was found to improve significantly with increase in work roll cross angle from 0^o to 1^o, with an associated decrease in rolling force. The effect of roll shifting (from 0 to 8mm) was not as significant as the roll cross angle. However, an increase in work roll shifting value achieved a similar decrease in rolling force as that of work roll cross angle. The effect of work roll shifting was also found to be maximum at an optimum roll speed of 0.0986 m/s for the desired thickness. Of all these parameters, the most significant effect of the strip shape profile was observed with variation of work roll cross angle. However, the rolling force can be a significantly reduced by either increasing the the work roll cross angle or work roll shifting.

Keywords: Rolling speed ratio, strip shape, work roll cross angle, work roll shifting.

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Authors: J. Marzbanrad, A. Yadollahi

Abstract:

In the present paper, Fatigue life assessment of an anti-roll bar component of a passenger vehicle, is investigated by ANSYS 11 software. A stress analysis is also carried out by the finite element technique for the determination of highly stressed regions on the bar. Anti-roll bar is a suspension element used at the front, rear, or at both ends of a car that reduces body roll by resisting any unequal vertical motion between the pair of wheels to which it is connected. As a first stage, fatigue damage models proposed by some well-known references and the corresponding assumptions are discussed and some enhancements are proposed. Then, fracture analysis of an anti-roll bar of an automobile is carried out. The analysed type of the anti-roll bar is especially important as many cases are reported about the fracture after a 100,000 km of travel fatigue and fracture conditions. This paper demonstrates fatigue life of an anti-roll bar and then evaluated by experimental analytically results from other researcher.

Keywords: Anti-roll bar, Fracture, Fatigue life, Random loading

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Authors: Yung Chang Chen, Po Yi Tsai, I An Lai

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The roll center is one of the key parameters for designing a suspension. Several driving characteristics are affected significantly by the migration of the roll center during the suspension-s motion. The strut/SLA (strut/short-long-arm) suspension, which is widely used in production cars, combines the space-saving characteristics of a MacPherson strut suspension with some of the preferred handling characteristics of an SLA suspension. In this study, a front strut/SLA suspension is modeled by ADAMS/Car software. Kinematic roll analysis is then employed to investigate how the rolling characteristics change under the wheel travel and steering input. The related parameters, including the roll center height, roll camber gain, toe change, scrub radius and wheel track width change, are analyzed and discussed. It is found that the strut/SLA suspension clearly has a higher roll center than strut and SLA suspensions do. The variations in the roll center height under roll analysis are very different as the wheel travel displacement and steering angle are added. The results of the roll camber gain, scrub radius and wheel track width change are considered satisfactory. However, the toe change is too large and needs fine-tuning through a sensitivity analysis.

Keywords: roll analysis, roll center height, steering, strut/SLA suspension, wheel travel

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Authors: Ch. Nerl, M. Wimmer, P. Hofer, E. Kaschnitz

Abstract:

The present article deals with a composite casting process that allows to produce bilayer AlSn6-Al strips based on the technique of horizontal continuous casting. In the first part experimental investigations on the production of a single layer AlSn6 strip are described. Afterwards essential results of basic compound casting trials using simple test specimen are presented to define the thermal conditions required for a metallurgical compound between the alloy AlSn6 and pure aluminium. Subsequently, numerical analyses are described. A finite element model was used to examine a continuous composite casting process. As a result of the simulations the main influencing parameters concerning the thermal conditions within the composite casting region could be pointed out. Finally, basic guidance is given for the design of an appropriate composite mould system.

Keywords: Aluminium alloys, composite casting, compound casting, continuous casting, numerical simulation

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Authors: Marco Actis Grande, Somlak Wannarumon

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This paper proposes the numerical simulation of the investment casting of gold jewelry. It aims to study the behavior of fluid flow during mould filling and solidification and to optimize the process parameters, which lead to predict and control casting defects such as gas porosity and shrinkage porosity. A finite difference method, computer simulation software FLOW-3D was used to simulate the jewelry casting process. The simplified model was designed for both numerical simulation and real casting production. A set of sensor acquisitions were allocated on the different positions of the wax tree of the model to detect filling times, while a set of thermocouples were allocated to detect the temperature during casting and cooling. Those detected data were applied to validate the results of the numerical simulation to the results of the real casting. The resulting comparisons signify that the numerical simulation can be used as an effective tool in investment-casting-process optimization and casting-defect prediction.

Keywords: Computer fluid dynamic, Investment casting, Jewelry, Mould filling, Simulation.

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Authors: Jung-Ho Moon, Tae Kwon Ha

Abstract:

Textures of AZ31 Mg alloy sheets were evaluated by using neutron diffraction method in this study. The AZ31 sheets were fabricated either by conventional casting and subsequent hot rolling or strip casting. The effect of warm rolling was investigated using the AZ31 Mg alloy sheet produced by conventional casting. Warm rolling of 30% thickness reduction per pass was possible without any side-crack at temperatures as low as 200^oC under the roll speed of 30 m/min. The initial microstructure of conventionally cast specimen was found to be partially recrystallized structures. Grain refinement was found to occur actively during the warm rolling. The (0002),(10-10) (10-11),and (10-12) complete pole figures were measured using the HANARO FCD (Neutron Four Circle Diffractometer) and ODF were calculated. The major texture of all specimens can be expressed by ND//(0001) fiber texture. Texture of hot rolled specimen showed the strongest fiber component, while that of strip cast sheet seemed to be similar to random distribution.

Keywords: Mg alloy, texture, pole figure, ODF, neutron diffraction, warm rolling.

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Authors: Mehdi Modabberifar, Behrouz Raad, Bahman Mirzakhani

Abstract:

Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.

Keywords: Die casting, finite element, flange.

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Authors: Z. Y. Jiang, H. B. Tibar, A. Aljabri

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Optimisation of the physical and mechanical properties of cold rolled thin strips is achieved by controlling the rolling parameters. In this paper, the factors affecting the asymmetrical cold rolling of thin low carbon steel strip have been studied at a speed ratio of 1.1 without lubricant applied. The effect of rolling parameters on the resulting microstructure was also investigated. It was found that under dry condition, work roll shifting and work roll cross angle can improve the strip profile, and the result is more significant with an increase of work roll cross angle rather than that of work roll shifting. However, there was no obvious change in microstructure. In addition, effects of rolling parameters on strip profile and microstructure have also been discussed.

Keywords: Reduction ratio, rolling speed ratio, strip shape, work rolls cross angle, work roll shifting.

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Authors: O. Srihakulung, Y. Soongsumal

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Among the chemicals used for ammunition production, TNT (Trinitrotoluene) play a significant role since World War I and II. Various types of military weapon utilize TNT in casting process. However, the TNT casting process for warhead is difficult to control the cooling rate of the liquid TNT. This problem occurs because the casting process lacks the equipment to detect the temperature during the casting procedure This study presents the temperature detected by infrared camera to illustrate the cooling rate and cooling zone of curing, and demonstrates the optimization of TNT condition to reduce the risk of air gap occurred in the warhead which can result in the destruction afterward. Premature initiation of explosive-filled projectiles in response to set-back forces during gunfiring cause by casting defects. Finally the study can help improving the process of the TNT casting. The operators can control the curing of TNT inside the case by rising up the heating rod at the proper time. Consequently this can reduce tremendous time of rework if the air gaps occur and increase strength to lower elastic modulus. Therefore, it can be clearly concluded that the use of Infrared Cameras in this process is another method to improve the casting procedure.

Keywords: Infrared camera, TNT casting, warhead, curing.

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Authors: Muhammad Kashif Siddiq, Fang Jian Cheng, Yu Wen Bo

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State-dependent Riccati equation based controllers are becoming increasingly popular because of having attractive properties like optimality, stability and robustness. This paper focuses on the design of a roll autopilot for a fin stabilized and canard controlled 122mm artillery rocket using state-dependent Riccati equation technique. Initial spin is imparted to rocket during launch and it quickly decays due to straight tail fins. After the spin phase, the roll orientation of rocket is brought to zero with the canard deflection commands generated by the roll autopilot. Roll autopilot has been developed by considering uncoupled roll, pitch and yaw channels. The canard actuator is modeled as a second-order nonlinear system. Elements of the state weighing matrix for Riccati equation have been chosen to be state dependent to exploit the design flexibility offered by the Riccati equation technique. Simulation results under varying conditions of flight demonstrate the wide operating range of the proposed autopilot.

Keywords: Fin stabilized 122mm artillery rocket, Roll Autopilot, Six degree of freedom trajectory model, State-dependent Riccati equation.

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Authors: Saeid Norouzi, Ali Shams, Hassan Farhangi, Alireza Darvish

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Hot tear cracking and residual stress are two different consequences of thermal stress both of which can be considered as casting problem. The purpose of the present study is simulation of the effect of casting shape characteristic on hot tearing and residual stress. This study shows that the temperature range for simulation of hot tearing and residual stress are different. In this study, in order to study the development of thermal stress and to predict the hot tearing and residual stress of shaped casting, MAGMASOFT simulation program was used. The strategy of this research was the prediction of hot tear location using pinpointing hot spot and thermal stress concentration zones. The results shows that existing of stress concentration zone increases the hot tearing probability and consequently reduces the amount of remaining residual stress in casting parts.

Keywords: Hot tearing, residual stress, simulation, investment casting.

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Authors: Kwok Tak Kit

Abstract:

With the growing trend of adoption of advanced technologies like, building information modeling, artificial intelligence, wireless network, the collaboration and integration of these technologies into digital twin become more prominent in architecture, engineering and construction (AEC) industry in view of the nature and scale of AEC industry which efficiently adopted the digital twin. Digital twin is provided to be effective for AEC professions for design and project management. The digital concept is continuously developing and it is vital for AEC professionals and other stakeholders to understand the digital twin concept and the adoption of various advanced building technologies related to the AEC industry. This paper is to review the application of digital twins application in project management in AEC industry and highlight the challenge of AEC partitioners faced by the revolution of technologies including digital twins and building information modelling (BIM) for further research and future study.

Keywords: Digital Twin, AEC, building information modeling, project management, internet of things.

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Authors: Pei-Hsing Huang, Wei-Ju Huang

Abstract:

Investment casting is commonly used in the production of metallic components with complex shapes, due to its high dimensional precision, good surface finish, and low cost. However, the process is cumbersome, and the period between trial casting and final production can be very long, thereby limiting business opportunities and competitiveness. In this study, we replaced conventional wax injection with stereolithography (SLA) 3D printing to speed up the trial process and reduce costs. We also used silicone molds to further reduce costs to avoid the high costs imposed by photosensitive resin.

Keywords: Investment casting, stereolithography, wax molding, 3D printing.

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Authors: Satish Kumar, Arun Kumar Gupta, Pankaj Chandna

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The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.

Keywords: Aluminium Casting, Pressure Die Casting, Taguchi Methodology, Design of Experiments

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Authors: Yang Xiaoliang, Liu Wei, Wang Hongbo, Zhao Yunfei

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Numerical investigation of the characteristics of an 80° delta wing in combined force-pitch and free-roll is presented. The implicit, upwind, flux-difference splitting, finite volume scheme and the second-order-accurate finite difference scheme are employed to solve the flow governing equations and Euler rigid-body dynamics equations, respectively. The characteristics of the delta wing in combined free-roll and large amplitude force-pitch is obtained numerically and shows a well agreement with experimental data qualitatively. The motion in combined force-pitch and free-roll significantly reduces the lift force and transverse stabilities of the delta wing, which is closely related to the flying safety. Investigations on sensitive factors indicate that the roll-axis moment of inertia and the structural damping have great influence on the frequency and amplitude, respectively. Moreover, the turbulence model is considered as an influencing factor in the investigation.

Keywords: combined force-pitch and free-roll, numericalsimulation, sensitive factors, slender delta wing, wing rock

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Authors: G. S. Walia, H. P. Singh, Padma D.

Abstract:

The integration of wide variety of communication services is made possible with invention of 3G technology. Code Division Multiple Access 2000 operates on various RF channel bandwidths 1.2288 or 3.6864 Mcps (1x or 3x systems). It is a 3G system which offers high bandwidth and wireless broadband services but its efficiency is lowered due to various factors like fading, interference, scattering, absorption etc. This paper investigates the effect of diversity (MRC), roll off factor in Root Raised Cosine (RRC) filter for the BPSK and QPSK modulation schemes. It is possible to transmit data with minimum Inter symbol Interference and within limited bandwidth with proper pulse shaping technique. Bit error rate (BER) performance is analyzed by applying diversity technique by varying the roll off factor for BPSK and QPSK. Roll off factor reduces the ISI and diversity reduces the Fading.

Keywords: CDMA2000, Diversity, Root Raised Cosine, Roll off factor.

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Authors: Taneli Eisto, Venlakaisa Hölttä, Katrine Mahlamäki, Janne Kollanus, Marko Nieminen

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Early supplier involvement (ESI) benefits new product development projects several ways. Nevertheless, many castuser companies do not know the advantages of ESI and therefore do not utilize it. This paper presents reasons why to utilize ESI in casting industry and how that can be done. Further, this paper presents advantages and challenges related to ESI in casting industry, and introduces a Casting-Network Collaboration Model. The model presents practices for companies to build advantageous collaborative relationships. More detailed, the model describes three levels for company-network relationships in casting industry with different degrees of collaboration, and requirements for operating in each level. In our research, ESI was found to influence, for example, on project time, component cost, and quality. In addition, challenges related to ESI, such as, a lack of mutual trust and unawareness about the advantages were found. Our research approach was a case study including four cases.

Keywords: Casting Industry, Collaboration Model, EarlySupplier Involvement, New Product Development.

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Authors: Temsiri Sapsaman, Anocha Bhocarattanahkul

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The maintenance of work rolls in hot strip processing has been lengthy and difficult tasks for hot strip manufacturer because heavy work rolls have to be taken out of the production line, which could take hours. One way to increase the time between maintenance is to improve the effectiveness of the work roll cooling system such that the wear and tear more slowly occurs, while the operation cost is kept low. Therefore, this study aims to improve the work roll cooling system by providing the manufacturer the relationship between the work-roll temperature reduced by cooling and the water flow that can help manufacturer determining the more effective water flow of the cooling system. The relationship is found using simulation with a systematic process adjustment so that the satisfying quality of product is achieved. Results suggest that the manufacturer could reduce the water flow by 9% with roughly the same performance. With the same process adjustment, the feasibility of finishing-mill-stand reduction is also investigated. Results suggest its possibility.

Keywords: Work-roll cooling system, hot strip process adjustment, feasibility study.

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Authors: Tanveer A. Khan, Xue Y. Deng, Yan K. Wang, Xu Si-Wen

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Experiments have been carried out at sub-critical Reynolds number to investigate free-to-roll motions induced by forebody and/or wings complex flow on a 30° swept back nonslender wings-slender body-model for static and dynamic (pitch-up) cases. For the dynamic (pitch-up) case it has been observed that roll amplitude decreases and lag increases with increase in pitching speed. Decrease in roll amplitude with increase in pitch rate is attributed to low disturbing rolling moment due to weaker interaction between forebody and wing flow components. Asymmetric forebody vortices dominate and control the roll motion of the model in dynamic case when non-dimensional pitch rate ≥ 1x10-2. Effectiveness of the active control scheme utilizing rotating nose with artificial tip perturbation is observed to be low in the angle of attack region where the complex flow over the wings has contributions from both forebody and wings.

Keywords: Artificial Tip Perturbation, ExperimentalInvestigations, Forebody Asymmetric Vortices, Non-slender Wings-Body Model, Wing Rock

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Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

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Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: Casting, cylinder liners, journal bearing, robot.

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Authors: M. Khodai, S. M. H. Mirbagheri

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In the Lost Foam Casting process, melting point temperature of metal, as well as volume and rate of the foam degradation have significant effect on the mold filling pattern. Therefore, gas generation capacity and gas gap length are two important parameters for modeling of mold filling time of the lost foam casting processes. In this paper, the gas gap length at the liquidfoam interface for a low melting point (aluminum) alloy and a high melting point (Carbon-steel) alloy are investigated by the photography technique. Results of the photography technique indicated, that the gas gap length and the mold filling time are increased with increased coating thickness and density of the foam. The Gas gap lengths measured in aluminum and Carbon-steel, depend on the foam density, and were approximately 4-5 and 25-60 mm, respectively. By using a new system, the gas generation capacity for the aluminum and steel was measured. The gas generation capacity measurements indicated that gas generation in the Aluminum and Carbon-steel lost foam casting was about 50 CC/g and 3200 CC/g polystyrene, respectively.

Keywords: gas gap, lost foam casting, photographytechnique.

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Authors: Ömer Faruk Baykoç, Ümit Sami Sakalli

Abstract:

In this paper, we propose a fuzzy aggregate production planning (APP) model for blending problem in a brass factory which is the problem of computing optimal amounts of raw materials for the total production of several types of brass in a period. The model has deterministic and imprecise parameters which follows triangular possibility distributions. The brass casting APP model can not always be solved by using common approaches used in the literature. Therefore a mathematical model is presented for solving this problem. In the proposed model, the Lai and Hwang-s fuzzy ranking concept is relaxed by using one constraint instead of three constraints. An application of the brass casting APP model in a brass factory shows that the proposed model successfully solves the multi-blend problem in casting process and determines the optimal raw material purchasing policies.

Keywords: Aggregate production planning, Blending, brasscasting, possibilistic programming.

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Authors: Zhao Cai-qi, Ma Jun

Abstract:

Twin steel plates-concrete composite shear walls are composed of a pair of steel plate layers and a concrete layer sandwiched between them, which have the characteristics of both reinforced concrete shear walls and steel plate shear walls. Twin steel plates-composite shear walls contain very high ultimsate bearing capacity and ductility, which have great potential to be applied in the super high-rise buildings and special structures. In this paper, we analyzed the basic characteristics and stress mechanism of the twin steel plates-composite shear walls. Specifically, we analyzed the effects of the steel plate thickness, wall thickness and concrete strength on the bearing capacity of the twin steel plates-composite shear walls. The analysis results indicate that: (1) the initial shear stiffness and ultimate shear-carrying capacity is not significantly affected by the thickness of concrete wall but by the class of concrete, (2) both factors significantly impact the shear distribution of the shear walls in ultimate shear-carrying capacity. The technique of twin steel plates-composite shear walls has been successfully applied in the construction of an 88-meter Huge Statue of Buddha located in Hunan Province, China. The analysis results and engineering experiences showed that the twin steel plates-composite shear walls have great potential for future research and applications.

Keywords: Twin steel plates-concrete composite shear wall, huge statue of Buddha, shear capacity, initial lateral stiffness, overturning moment bearing.

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Authors: Alfrina Marwan, Erna Sulistyawati

Abstract:

Class III malocclusion shows both skeletal and dentoalveolar component. Sketal Class III malocclusion can have variants in different region, maxilla or mandibular. Skeletal Class III malocclusion during growth period is considered to treat to prevent its severity in adulthood. Orthopedics treatment of skeletal Class III malocclusion in growing patient can be treated by using reverse twin block with expansion screw to modify the growth pattern. The objective of this case report was to describe the functional correction of skeletal Class III maloclussion using reverse twin block with expansion screw in growing patient. A patient with concave profile came with a chief complaint of aesthetic problems. The cephalometric analysis showed that patient had skeletal Class III malocclusion (ANB -5⁰, SNA 75º, Wits appraisal -3 mm) with anterior cross bite and deep bite (overjet -3 mm, overbite 6 mm). In this case report, the patient was treated with reverse twin block appliance with expansion screw. After three months of treatment, the skeletal problems have been corrected (ANB -1°), overjet, overbite and aesthetic were improved. Reverse twin block appliance with expansion screw can be used as orthopedics treatment for skeletal Class III malocclusion in growing patient and can improve the aesthetic with great satisfaction which was the main complaint in this patient.

Keywords: Growing patient, maxilla retrognatism, reverse twin blocks, skeletal Class III malocclusion.

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Authors: L. Chaussy, M. Nouvel

Abstract:

Workload of the system engineers during Integration Validation Verification process of Electronic Warfare Systems (EWS) is growing with complexity of the systems and with the diversity of tested cases (diversity of operational scenario in front of EWS). Even if the use of Digital Twin makes easier conception and development phases in term of planning and test equipment availability, time to analyze tests results is still too long and too complex. The idea to reduce the system engineer’s workload and improve test coverage is to introduce some intelligent and aid-analysis algorithms to improve this step.

Keywords: Analysis tools, automatic testing, digital twin, electronic warfare system.

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Authors: P. Meethum, C. Suvanjumrat

Abstract:

Many aluminum motorcycle parts produced by a high pressure die casting. Some parts such as fuel caps were a thin and complex shape. This part risked for porosities and blisters on surface if it only depended on an experience of mold makers for mold design. This research attempted to use CAST-DESIGNER software simulated the high pressure die casting process with the same process parameters of a motorcycle fuel cap production. The simulated results were compared with fuel cap products and expressed the same porosity and blister locations on cap surface. An average of absolute difference of simulated results was obtained 0.094 mm when compared the simulated porosity and blister defect sizes on the fuel cap surfaces with the experimental micro photography. This comparison confirmed an accuracy of software and will use the setting parameters to improve fuel cap molds in the further work.

Keywords: Aluminum, die casting, fuel cap, motorcycle.

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Authors: Ali A. Al-Jazaairry, Tahsin T. Sabbagh

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Presence of cavities in soil predictably induces ground deformation and changes in soil stress, which might influence adjacent existing pile foundations, though the effect of twin cavities on a nearby pile needs to be understood. This research is an attempt to identify the behaviour of piles subjected to axial load and embedded in cavitied clayey soil. A series of finite element modelling were conducted to investigate the performance of piled foundation located in such soils. The validity of the numerical simulation was evaluated by comparing it with available field test and alternative analytical model. The study involved many parameters such as twin cavities size, depth, spacing between cavities, and eccentricity of cavities from the pile axis on the pile performance subjected to axial load. The study involved many cases; in each case, a critical value has been found in which cavities’ presence has shown minimum impact on the behaviour of pile. Load-displacement relationships of the affecting parameters on the pile behaviour were presented to provide helpful information for designing piled foundation situated near twin underground cavities. It was concluded that the presence of the cavities within the soil mass reduces the ultimate capacity of pile. This reduction differs according to the size and location of the cavity.

Keywords: Axial load, clay, finite element, pile, twin cavities, ultimate capacity.

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Authors: Lenka Hurtalová, Eva Tillová, Mária Chalupová, Juraj Belan, Milan Uhríčik

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The secondary alloy A226 is used for many automotive casting produced by mould casting and high pressure die casting. This alloy has excellent castability, good mechanical properties and cost-effectiveness. Production of primary aluminium alloys belong to heavy source fouling of life environs. The European Union calls for the emission reduction and reduction in energy consumption therefore increase production of recycled (secondary) aluminium cast alloys. The contribution is deal with influence of recycling on the quality of the casting made from A226 in automotive industry. The properties of the casting made from secondary aluminium alloys were compared with the required properties of primary aluminium alloys. The effect of recycling on microstructure was observed using combination different analytical techniques (light microscopy upon black-white etching, scanning electron microscopy - SEM upon deep etching and energy dispersive X-ray analysis - EDX). These techniques were used for the identification of the various structure parameters, which was used to compare secondary alloy microstructure with primary alloy microstructure.

Keywords: A226 secondary aluminium alloy, deep etching, mechanical properties, recycling foundry aluminium alloy.

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Authors: M. Jalali Azizpour, S.Norouzi H. Mohammadi Majd

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In this paper, the babbitting of a bearing in boiler feed pump of an electromotor has been studied. These bearings have an important role in reducing the shut down times in the pumps, compressors and turbines. The most conventional method in babbitting is casting as a melting method. The comparison between thermal spray and casting methods in babbitting shows that the thermal spraying babbitt layer has better performance and tribological behavior. The metallurgical and tribological analysis such as SEM, EDS and wet chemical analysis has been made in the Babbitt alloys and worn surfaces. Two type of babbitt materials: tinbase and lead-base babbitt was used. The benefits of thermally sprayed babbitt layers are completely clear especially in large bearings.

Keywords: Thermal spray, Babbitting, Bonding, Bearing, BFP, CWP

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