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Manufacturing and automation as a recovery path toward sustainable growth
Published in Harish Hirani, Technological Innovations for Effective Pandemic Response, 2023
Casting is the most economical method to produce complex shape components (i.e., automotive, machine tools, pipe fittings, textile machinery) that would be difficult to make by other methods. Cast iron and aluminum are most commonly processed metals through this route. These metals in molten state are poured into a mold having the cavity of the desired shape so that metal takes an appropriate form on its solidification. With appropriate science of metal casting bronze, brass, steel, magnesium, zinc, etc. have also been casted [9].
Motor Frame Design
Published in Wei Tong, Mechanical Design and Manufacturing of Electric Motors, 2022
Common casting materials include aluminum, iron, copper, magnesium, zinc, and steel alloys. Among them, aluminum is the most popular material extensively used by motor manufacturers. Benefited with a low melting temperature, high liquidity, lightweight, high thermal conductivity, and other good casting characteristics, aluminum alloys have been commonly used for manufacturing motor housings, endbells, and other components. Furthermore, reusability is one of the principal advantages of aluminum. With the improvement of aluminum alloys and casting processes and good balance between mechanical properties and lightness, it is expected that more and more aluminum-casting parts will be demanded by the motor industry.
Study and Control of Shrinkage in Gearbox Sand Casting Using Simulation and Experimental Validation
Published in R.S. Chauhan, Kavita Taneja, Rajiv Khanduja, Vishal Kamra, Rahul Rattan, Evolutionary Computation with Intelligent Systems, 2022
Sarabjit Singh, Rajesh Khanna, Neeraj Sharma
Today, the casting process has become an integral part of many sectors such as automotive, agriculture, heavy engineering, construction, and machinery. Various casting manufacturing processes are being used worldwide on the basis of various factors such as mass production or batch production, economic considerations, surface finish, and design intricacy. The main casting processes include sand casting, die casting, sand-shell casting, and investment casting.
The sand-casting process: a meta-heuristic approach for an environment-friendly and profitable scheduling
Published in International Journal of Production Research, 2023
Sand casting is one of the older techniques and one of the most commonly used casting process. Sand casting foundries in the world are nowadays almost 20,000, producing about 70 millions ton of parts every year (Assofond 2020). The overall process is depicted in Figure 1. Sand casting uses sand as the primary moulding material. The sand grains are mixed with a small amount of other materials (such as clay and water) to improve mould ability and cohesive strength and are then packed around a pattern that has the shape of the desired casting. The pattern is then removed before pouring. Castings are often required to have holes, recesses, etc. of various sizes and shapes, that are obtained through cores. Cores are made of sand compacted into the desired shape and must be included in the mould cavity before pouring so that the molten metal will flow and solidify between the mould cavity and the core to form the casting’s external and internal surfaces.
A study on the construction of die-casting production prediction model by machine learning with Taguchi methods
Published in Journal of the Chinese Institute of Engineers, 2023
Yung-Tsan Jou, Riana Magdalena Silitonga, Ronald Sukwadi
For a factory, production is an essential part. The output, type, and quality of production are crucial indicators for evaluating the quality of a product. This study uses the manufacturing parameters in the production process to predict whether there may be defects in the production and assist the operators in increasing their vigilance during inspections. Die casting is a metal casting process. Compared with other casting methods, it has many characteristics: high productivity, high precision dimensions, high mechanical strength, and thin-wall castings. It is one of the most widely used casting processes and its most common application in the automotive-related industries. Therefore, this study uses actual production data from domestic automobile manufacturing plants as the verification data to evaluate which machine learning algorithm is most suitable for the aluminum die-casting production industry.
Constitutive equation and microstructure analysis of Al0.6CoCrFeNi high entropy alloy during hot deformation
Published in Philosophical Magazine, 2022
Jingyi Wang, Pan Yang, Dan Wang
CoCrFeNi quaternary alloy has a simple face-centered cubic structure and good plasticity, but its strength and hardness are low. To improve its strength, an appropriate amount of Al can usually be added because the radius of Al atom is very different from that of other atoms, which causes strong lattice distortion and improves its strength. Finally, AlxCoCrFeNi high entropy alloy was obtained [11]. AlxCoCrFeNi high entropy alloy is a typical HEA system. The structure and properties will change with the content of Al. When 0 < x < 0.3, the alloy is face-centred cubic structure, when 0.5 < x < 0.7, the alloy is face-centred cubic + body-centered cubic structure, and when 0.9 < x < 1.8, the alloy is body-centred cubic structure [12,13]. As all known, face-centred cubic structure has good plasticity and toughness, and body-centred cubic structure has good strength and hardness [14,15]. Al0.6CoCrFeNi high entropy alloy has FCC + BCC dual-phase structure, so it has high strength and hardness and good plastic toughness. Al0.6CoCrFeNi high entropy alloy has more development potential than a single high entropy alloy. As we all know, casting alloys usually have casting defects such as shrinkage porosity, coarse grain size, and uneven structure. To obtain materials with uniform structure, refined grains, and excellent properties, it is usually carried out thermomechanical processing on cast alloys to obtain ideal properties [16–18].