Livarski vestnik 60/2013 nr. 4
Konrad Weiss,
RWP GmbH, Nemčija
P. Malinowski, J. S. Suchy
University of Science and Technology, al. Mickiewicza 30, 30-059 Krakow, Poland
Zdenka Zovko Brodarac, Faruk Unkić - University of Zagreb Faculty of Metallurgy, Aleja narodnih heroja 3, 44103 Sisak, Croatia
Davor Stanić - CIMOS, P.P.C. Buzet d.o.o., Most 24, 52420 Buzet, Croatia
B. Karpe, B. Kosec, T. Kolenko, G. Brovč, M.Bizjak
University of Ljubljana, Faculty of Natural Sciences and Engineering, Aškerčeva cesta 12, Ljubljana, Slovenia
RWP GmbH, Nemčija
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P. Malinowski, J. S. Suchy
SIMULATION FOR FOUNDRY PROCESSES - HISTORY, STATE OF THE ART, FUTURE DEVELOPMENT -
ABSTRACT
Today development projects require the use of virtual reality as one of the tools to speed up the development time. The virtual reality programmes are combining geometry and requirements inside of a well developed visual room. The way of the connectivity between the requirements and the geometry can be either high complex with links to different calculation programmes or in a more simple way just in an organizational connection.
The foundry industry as one of the basic producers of the e.g. automotive parts tried already more than 50 years ago to use standby systems to got more knowledge and more confidence in the foundry process. When computers came up and get more and more popular also the foundry industry required the use of these tools. Today we use a couple of different simulation tools, without knowing the basics and roots of these tools. To use the tools in the right way we have still to know and understand the basics.
Here we start with this article. We will give a short overview of the history and the basics used by the foundry related simulation programmes. The next step will show the state of the art and will give some remarks of the usage and the success of the foundry simulation world. In the third part of this overview we tried to find out the necessities and the possibilities in the virtual reality to find the right place in the concert of the IT support in the next decade. Simulation is today one important part of the virtual reality. New component development is no longer possible without the help of the different IT capabilities. So the development process with the requirements starts already in a very early stage using the different simulation tools. Still the rules of the development and planning are valid. Beginning with the initial design the block of the virtual reality starts and will lead the construction after some virtual optimization to the first release.
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P. Malinowski, J. S. Suchy
University of Science and Technology, al. Mickiewicza 30, 30-059 Krakow, Poland
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Zdenka Zovko Brodarac, Faruk Unkić - University of Zagreb Faculty of Metallurgy, Aleja narodnih heroja 3, 44103 Sisak, Croatia
MASTERDB – TECHNOLOGICAL KNOWLEDGE MANAGEMENT SYSTEM
ABSTRACT
The MasterDB system is designed to monitor the flow of information between subordinate servers SimulationDB. This allows casting technology developed in one branch to be quickly applied in another branch of the company. The MasterDB system is used to efficiently manage technological knowledge in the entire casting company. It consists of SimulationDB subsystems.
A technological knowledge base SimulationDB stores detailed information from each step of the production process
SimulationDB – Database for Foundry Engineers has several advantages like:
• Technological data are gathered in one place,
• Easy access to simulation results,
• Comparison virtual and real technology,
• Training young and inexperienced technologists,
• Easy search and analyze data
• Create new technology based on information from SimulationDB system
Advantages of the MasterDB system:
• Sharing developed technological knowledge with other branches of the company,
• Easier access to specialized technological knowledge,
• Improvement of the company’s competitiveness and efficiency,
• Saving resources – there is no need to involve several teams of technologists in order to solve the same issue.
Keywords:
Database for simulation results, Knowledge base, Production process management
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Zdenka Zovko Brodarac, Faruk Unkić - University of Zagreb Faculty of Metallurgy, Aleja narodnih heroja 3, 44103 Sisak, Croatia
Davor Stanić - CIMOS, P.P.C. Buzet d.o.o., Most 24, 52420 Buzet, Croatia
INVESTIGATION OF AlSi9MgMn ALLOY SOLIDIFICATION BY THERMAL ANALYSIS
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HEAT TRANSFER ANALYSES OF THE FREE JET MELT SPINNING PROCESS
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INVESTIGATION OF AlSi9MgMn ALLOY SOLIDIFICATION BY THERMAL ANALYSIS
ABSTRACT
Since aluminium alloys have found their wide application in numerous industries, quality requirements allocated new features regarding microstructural, mechanical and technological properties. Novel multicomponent AlSi9MgMn alloy intended for high pressure die casting has been investigated due to unusual chemical composition. Since this alloy has not been classified in international standard, only briefly described in manufacturer norm, it represents challenge for understanding of its solidification mechanism. Main characteristics of an alloy are related to high manganese and low iron content, and in spite of this, high mechanical properties, first of all, ductility.
The aim of this article was to establish solidification sequence of AlSi9MgMn alloy with high Mn addition by numerical calculation of equilibrium phase diagram and differential scanning calorimetry and reconnection of thermodynamic parameters with obtained microstructure. Thermodynamic calculation revealed solidification sequence with corresponded temperatures as follows: precipitation of high temperature AlxMnyFezSiu phase, development of primary dendrite network, main eutectic reaction and finally, in solid state, secondary eutectic phase Mg2Si. Differential scanning calorimetry enables exact temperatures of phase transformations determination. Thermodynamic investigation does not indicate any reaction in solid state. Microstructure investigation by optical and electron microscopy indicates presence of particular phases: primary aluminium dendrites (αAl), high temperature Al15(MnFe)3Si2 and Al5FeSi phases, main eutectic αAl+βSi, intermetallic iron-magnesium phase Al8Mg3FeSi6 developed from needle-like Al5FeSi phases and secondary eutectic phase on the magnesium base in a form of binary eutectic (αAl + Mg2Si).
Synergy of performed thermodynamic and microstructural investigation enables exact solidification sequence establishment with reaction and corresponding temperatures.
Key words: AlSi9MgMn alloy, solidification sequence, thermal analysis, microstructure
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University of Ljubljana, Faculty of Natural Sciences and Engineering, Aškerčeva cesta 12, Ljubljana, Slovenia
HEAT TRANSFER ANALYSES OF THE FREE JET MELT SPINNING PROCESS
ABSTRACT
Single roll melt spinning is the most commonly used process for the production of rapidly solidified thin metal ribbons. Microstructure development over the ribbon thickness mostly depend on the ribbon thickness itself, contact resistance between the melt and chilling wheel, heat transfer in the melt and the wheel, and nucleation and crystal growth characteristics of the particular casting material. The calculations show that contact resistance between metal melt and chilling wheel has a great influence on melt cooling and wheel heating rate, and must not be neglected in heat transfer calculations, even if its value is very low. New method for determining contact resistance through variable heat transfer coefficient is introduced which takes into account physical properties of the casting material, process parameters and contact time/length between metal melt and chilling wheel. It can be concluded from the results that process parameters which determine the thickness of the melt puddle in the downstream have major influence on cooling and solidifying rate of the ribbon. For the propose of industrial continuous casting of larger material quantities, heat balance of the wheel is calculated and influence of the chill wheel cooling mode on cooling rate of metallic ribbon is analyzed.
Key words: Rapid Solidification, Metallic Materials, HeatBalance, Heat Transfer Coefficien, Numerical Modeling
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