Beruflich Dokumente
Kultur Dokumente
Ioan Ciobanu, Sorin Munteanu, Aurel Crisan, Tibor Bedo, Vlad Monescu
Transilvania University of Brasov, Romania
Abstract
Riser sizing optimization is based on the analysis of riser sis must be based on solidification time maps (and not on the
operation. Casting solidification simulation software allows temperature maps at the end of solidification), on the time
this analysis to be done without the consumption of materi- of interruption of communication between riser and casting
als, energy and labor. This paper presents a methodology and on the amount of the useful liquid alloy available in the
to analyze riser operation to optimize riser size during met- riser until the casting solidifies. Our study shows that the
alcasting. This three-part paper includes: (1) establishing solidification analysis must be undertaken on the basis of the
the test criteria during the riser operation analysis; (2) ex- real solidification modulus and not on the geometric solidi-
emplification of the riser operation analysis by simulation, fication modulus.
using a steel casting; and (3) experimental verification of the
results. The findings suggest that the riser operation analy- Keywords: casting, riser, alloy solidification, simulation
Riser systems design establishes the riser position and size The study on shrinkage formation mechanism in castings
in relation to the casting. Riser optimization refers to analy- leads to the following 9 criteria to evaluate the riser operation:
sis of the casting solidification with different types of risers
(position and dimensions) and choosing the most favorable These criteria form the basis of studies to optimize the riser
variant from a technological and economical point of view. systems:
The optimal variant is chosen based on the analysis of the Riser Position and Height
riser operation and the liquid alloy consumption during cas- Risers are placed in the vicinity of casting hot spots. De-
ting. The development of software for casting solidification pending on the geometry and position of the hot spots, each
simulation provides the opportunity to carry out advanced hot spot may be equipped with a riser or one riser can simul-
studies on riser systems operation.1,2,3,4 It is thus possible to taneously feed several hot spots. Liquid alloy flows from the
make optimizations, without actually producing castings that riser to the casting based on the principle of communicating
require labor, materials and energy. In casting workshops, vessels (in communicating vessels the fluid levels are of the
although riser dimensions are established by simulation, the same height regardless of the shape of the vessels).1 Con-
riser operation and the economic aspects are not studied in sequently the riser should be higher than the casting, and it
much detail. Often industrial users do not take full advan- is recommended to position the casting with the hot spots
tage of all the possibilities offered by casting solidification located at the top. As a result the riser has small height.
simulation software. Many times in industrial practice, the
casting solidification analysis and riser design are based only 6HTXHQFHRIWKH/LTXLG$OOR\6ROLGL¿FDWLRQ
on the analysis of the temperature distribution in the cast- For proper functioning of the riser it is necessary to control
ing–riser system at the end of alloy solidification.5,6,7,8 Also, the alloy solidification in the following sequence: casting-
rarely is the best casting variant determined by comparative riser neck-riser. If the riser neck solidifies last, the shrinkage
economic analysis. cavity is formed in the riser neck and this may affect the
soundness of the casting. If the riser neck solidifies faster
The objective of this work is to provide foundry engineers than the casting, then shrinkage is formed in the casting.
and metalcasters with a systematic method to analyze the
riser operation based on computer simulation of casting so- The solidification sequence of the casting-riser system can
lidification. This paper consists of three parts: be quickly appreciated calculating the solidification modu-
• establishing the criteria for riser operation analysis; lus. The notion of solidification modulus was introduced by
• exemplifying the working methodology; Chvorinov.9 Chvorinov’s relationship to calculate the solidi-
• experimental verification fication modulus is as follows:
MC:MN:MR= 1:1,1:1,2 Eqn. 3 In order to ensure ensure riser efficiency, the amount of use-
ful liquid alloy in the riser until complete solidification of
Where; MC = real solidification modulus of casting; MN = the casting, must be equal or greater than the alloy contracti-
real solidification modulus of riser neck; MR = real solidifi- on at solidification. The volume of useful liquid alloy in the
cation modulus of riser. The real solidification modulus (M) riser required to compensate the alloy contraction (VULR) is
is correlated with the solidification time (tS) by the square calculated as:
root law of solidification, expressed in the relationship: 2,9,12
VLUM ≥ β (VC + VN+ VR ) / 100 = β (VTOT) / 100 Eqn. 6
Eqn. 4
Methodology For Riser Operation Analysis The casting subject of this case study is shown in Figure
2. This presents at the upper end a thicker zone (hot spot)
Based on the above considerations the methodology for riser having the inscribed circle diameter of 48mm (1.89 in.) and
operation analysis includes the following steps: the geometric solidification modulus MGC = 14.2mm (0.559
a) A preliminary analysis of casting solidification in), (calculated using Eqn 1). The geometric solidification
to identify the position of the hot spots. For this modulus was calculated in order to highlight the differences
purpose, the analysis of the casting solidification from the real solidification modulus. The real solidification
The dimensions of
riser and riser neck
for the variants stud-
ied by simulation
are given in Table
1. Table 2 shows the
values of the real so- Figure 3. Schematic of the mould and casting-riser
lidification modulus Figure 2. Test casting dimensions. system.
The results on the volume of useful liquid alloy available in Figures 7, 9, 11, 13, 15 & 17 show the positioning of the
the riser until solidification (VULR), the maximum solidifica- useful liquid alloy inside the riser. If the amount of liquid
tion contraction possible to compensate by riser (βMAX) and alloy is insufficient, the riser size must be increased. These
the index liquid alloy use in riser (I.U.) are given in Table 4. figures also highlight if the liquid alloy can entirely reach
Figures 4-17 show the graphical representations of the simu- the casting. This is only possible if there is an unsolidified
lation results: The isotherms in the mold assembly at the end channel to the end of casting solidification. The surface cor-
of alloy solidification, the solidification time map and the use- responding to useful liquid alloy in these figures is different
from that corresponding to shrinkages because it includes
the amount of alloy solidified in the mushy zone.
Figure 8. Solidi¿cation times contour map. Variant V3± Figure 9. Useful liquid alloy available in riser until casting
riser dR x HR =80 x 136 mm, riser necN section bN x hN = solidi¿cation. Variant V3-riser dR x HR =80mm x 136mm,
48 x 48mm. riser necN section bN x hN = 48 x 48mm.
Figure 10. Solidi¿cation times contour map. Variant V4± Figure 11. Useful liquid alloy available in riser until
riser dR x HR =104 x 144 mm, riser necN section bN x hN = casting solidi¿cation. Variant V4-riser dR x HR =104mm x
32 x 32mm. 104mm, riser necN section bN x hN = 32 x 32mm.
Figure 14. Solidi¿cation times contour map. Variant V6± Figure 15. Useful liquid alloy available in riser until
riser dR x HR = 64 x 152mm, riser necN section bN x hN = casting solidi¿cation. Variant V6-riser dR x HR = 64mm x
48 x 48mm. 152mm, riser necN section bN x hN = 48 x 48mm.
Figure 16. Solidi¿cation times contour map. Variant V7± Figure 17. Useful liquid alloy available in riser until
riser dR x HR =88 x 144mm, riser necN section bN x hN = casting solidi¿cation. Variant V7-riser dR x HR = 88mm x
48 x 48mm. 144mm, riser necN section bN x hN = 48 x 48mm.
Experimental Results
Conclusions
Figure 20. Sectioned views of six experimental castings(V1, 2,4, 5, 6 & 7).
Technical Review & Discussion system and hot spot positions. This is explained by the short
filling time (under 10 seconds), the temperature equalization
Riser Analysis Using Casting Simulation during filling (due to the forced convection during filling),
7HFKQLTXHVGXULQJ6ROLGL¿FDWLRQ the small sections of the riser pipe and its distance from cas-
Ioan Ciobanu, Sorin Munteanu, Aurel Crisan, ting.
Tibor Bedo, Vlad Monescu Transilvania University of
Brasov, Romania Reviewer: The use of round risers is common foundry prac-
tice. Why were they not used in this study?
Editor’s note: The published paper was originally submitted
in three parts dealing with both iron and steel casting. The Authors: Riser patterns of square section were used, both
authors have modified this IJMC paper to focus strictly on in simulations and in experiments because they are easi-
steel casting. er to make by manual cutting in polystyrene. We believe
that the methodology for analyzing the riser operation is
Reviewer: The study seems to indicate that the gating sy- not influenced by the riser geometry. Of course if we use
stem and filling process don’t have significant influence on a cylindrical riser, the yield of liquid alloy used would be
solidification time. Were the simulations specific to steel slightly larger. For example, in the case of variant 7, this
castings? What thermal characteristics were used? index will be IU = 40.68% (against IU =35.47% for riser
with square section).
Authors: When we revised the paper, we re-ran all simulati-
ons for steel castings, taking into account the gating system Reviewers: How were the simulations condition such as the
in the same simulation conditions (temperature, mold type). cooling co-efficient validated?
Thermal characteristics of the mold and liquid steel consi-
dered in the simulation are those used by the most popular Authors: The cooling coefficient values used to calculate
commercial software. The results showed that in the case of the real solidification modulus are adopted depending on
the small casting we studied, the gating system and filling the local cooling conditions (hot corners, parallel surfaces
process don’t have significant influence on solidification, in neighboring). This is based on previous calculations and ex-
terms of solidification time, temperature distribution in the periments that are not the subject of this paper.