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Optimal riser design for metal castings

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Abstract

The optimal design of a casting rigging system is considered. The casting geometry is systematically modified to minimize the gate and riser volume, while simultaneously ensuring that no porosity appears in the product. In this approach, we combine finite-element analysis of the solidification heat-transfer process with design sensitivity analysis and numerical optimization to systematically improve the casting design. Methods are presented for performing the sensitivity analysis, including the sensitivity of important solidification parameters such as freezing time, temperature gradient, and cooling rate. We also present methods for performing Newton-Raphson iteration for solidification models that use the boundary-curvature method to represent the sand mold. Finally, the methods are applied to design risers for an L-shaped steel plate to control microporosity and for a steel hammer to control macroporosity. It is demonstrated that the size of a conventionally designed riser can be reduced by a significant amount while retaining the quality of the cast product.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, University of Illinois, 61801, Urbana-Champaign, IL

    T. E. Morthland (Graduate Student) & J. A. Dantzig (Associate Professor)

  2. Department of Mechanical and Industrial Engineering and Theoretical and Applied Mechanics, University of Illinois, 61801, Urbana-Champaign, IL

    D. A. Tortorelli (Assistant Professor)

  3. General Electric, 44094, Cleveland, OH

    P. E. Byrne (Management Trainee)

Authors
  1. T. E. Morthland
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  2. P. E. Byrne
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  3. D. A. Tortorelli
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  4. J. A. Dantzig
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Additional information

Formerly Graduate Student, Department of Mechanical and Industrial Engineering, University of Illinois

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Morthland, T.E., Byrne, P.E., Tortorelli, D.A. et al. Optimal riser design for metal castings. Metall Mater Trans B 26, 871–885 (1995). https://doi.org/10.1007/BF02651733

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  • DOI: https://doi.org/10.1007/BF02651733

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