Casting : an analytical approach

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Title:

Personal Author:

Reikher, Alexandre

Series:

Engineering materials and processes

Publication Information:

London : Springer, 2007

Physical Description:

xi, 177 p. : ill. ; 24 cm. + 1 CD-ROM (12 cm.)

ISBN:

9781846288494

9781846288500

General Note:

Accompanied by CD-ROM : CP 013085

Available in online version

Subject Term:

Founding

Added Author:

Barkhudarov, Michael R. (Michael Rudolf)

Added Title:

[electronic resource]

Electronic Access:

Fulltext

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Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010167389	TS230 R44 2007	Open Access Book	Book	Searching... Unknown

This book is the result of 40 years of the combined authors' experience in mechanical and fluid dynamics engineering. It gives an overview of product and process development from the analytical standpoint. This book has not been intended to revolutionize the casting industry. The principals of fluid dynamics and static mechanics were largely developed in the nineteenth century, but process development still largely remains a trial and error method. This book is intended to underline the principals of strength of materials and fluid dynamics that are the foundation of the casting product and process development. This book has been written as a resource and design tool for product and process engineers and designers who work with aluminium castings. It combines many aspects of product and process development, which include the basic principals of static mechanics and fluid dynamics as well as completely developed applications allowing solving problems at every stage of the development process. This book has five main parts: (1) overview of casting processes, (2) fluid dynamics, (3) strength of materials, (4) sand casting, permanent mould, and die casting process development, and (5) quality control.

Author Notes

Dr Alexandre Reikher is a product design leader at Albany Chicago Co. Pleasant Prairie WI (USA), the company he joined in 1997. He is responsible for all aspects of product design, Finite Element and Computational Fluid Dynamics analysis. Dr Reikher received his PhD in Engineering from Kennedy Western University (USA) in 2005 and a Master of Science from Kishinev Politechnic Institute (USSR, Moldova) in 1985. He has 20 years experience in the die cast industry.

Dr Michael R. Barkhudarov is the Vice President of Research & Development at Flow Science, Inc., Santa Fe, NM (USA), the company he joined in 1994. As Vice President of Research & Development, he is responsible for all aspects of extension and advancement of the company's core computational fluid dynamics technology. Dr Barkhudarov received his PhD in Material Science from the University of Sheffield (UK) in 1995 and a Masters of Science in Mechanical Engineering from Lomonosov State University of Moscow in 1985.

1 Casting of Light Metals	p. 1
1.1 Casting Processes	p. 1
1.2 Sand Casting	p. 1
1.2.1 Gating System	p. 2
1.2.2 Risers and Chills	p. 2
1.3 Permanent Mould	p. 3
1.3.1 Gravity Casting	p. 4
1.3.2 Low-pressure Permanent Mould Casting	p. 4
1.3.3 Counterpressure Casting	p. 4
1.4 Die Casting	p. 5
1.4.1 Die-cast Process	p. 5
1.4.2 Die-cast Dies	p. 8
1.4.3 Runner System	p. 8
1.4.4 Cavity of Die-cast Die	p. 11
1.4.5 Air Ventilation System	p. 11
1.4.6 Ventilation Blocks	p. 12
2 Introduction to Fluid Dynamics	p. 13
2.1 Basic Concepts	p. 13
2.1.1 Pressure	p. 13
2.1.2 Viscosity	p. 14
2.1.3 Temperature and Enthalpy	p. 16
2.2 Equations of Motion	p. 18
2.3 Boundary Conditions	p. 19
2.3.1 Velocity Boundary Conditions at Walls	p. 20
2.3.2 Thermal Boundary Conditions at Walls	p. 20
2.3.3 Free Surface Boundary Conditions	p. 21
2.4 Useful Dimensionless Numbers	p. 23
2.4.1 Definitions	p. 23
2.4.2 The Reynolds number	p. 24
2.4.3 The Weber Number	p. 24
2.4.4 The Bond Number	p. 25
2.4.5 The Froude Number	p. 25
2.5 The Bernoulli Equation	p. 26
2.6 Compressible Flow	p. 26
2.6.1 Equation of State	p. 27
2.6.2 Equations of Motion	p. 28
2.6.3 Specific Heats	p. 29
2.6.4 Adiabatic Processes	p. 31
2.6.5 Speed of Sound	p. 31
2.6.6 Mach Number	p. 33
2.6.7 The Bernoulli Equation for Gases	p. 33
2.7 Computational Fluid Dynamics	p. 35
2.7.1 Computational Mesh	p. 35
2.7.2 Numerical approximations	p. 36
2.7.3 Representation of Geometry	p. 38
2.7.4 Free Surface Tracking	p. 39
2.7.5 Summary	p. 41
3 Part Design	p. 43
3.1 Design of Light Metal Castings	p. 43
3.2 Static Analysis	p. 43
3.2.1 Moment of an Area	p. 44
3.2.2 Moment of Inertia of an Area	p. 44
3.3 Loading	p. 46
3.4 Stress Components	p. 47
3.4.1 Linear Stress	p. 48
3.4.2 Plane Stress	p. 50
3.4.3 Mohr's Circle	p. 51
3.5 Hooke's Law	p. 55
3.6 Saint-Venant's Principle	p. 56
3.7 Criteria of Failure	p. 57
3.7.1 Ductile Material Failure Theory	p. 58
3.7.2 Brittle Material Failure Theory	p. 58
3.8 Beam Analysis	p. 58
3.8.1 Free Body Diagram	p. 67
3.8.2 Reactions	p. 67
3.9 Buckling	p. 68
3.10 Bending Stresses	p. 71
3.10.1 Normal Stresses in Bending	p. 72
3.10.2 Shear Stress	p. 74
3.11 Stresses in Cylinders	p. 76
3.12 Press-fit Analysis	p. 82
3.13 Thermal Stresses	p. 86
3.14 Torque	p. 87
3.15 Stress Concentration	p. 93
3.16 Fatigue	p. 94
3.17 MATLAB" Functions Used in Chapter 3	p. 96
4 Process Design	p. 97
4.1 Evaluation of Dimensionless Numbers	p. 97
4.1.1 Gravity Pour	p. 98
4.1.2 High-pressure Die Casting: Slow Shot	p. 98
4.1.3 High-pressure Die Casting: Fast Shot	p. 99
4.2 Flow in Viscous Boundary Layer	p. 100
4.3 The Bernoulli Equation	p. 102
4.3.1 Stagnation, Dynamic and Total Pressure	p. 102
4.3.2 Gravity Controlled Flow	p. 103
4.3.3 Flow in the Runner System	p. 104
4.3.4 Filling Rate	p. 106
4.4 Flow in a Shot Cylinder	p. 108
4.5 Gas Ventilation System	p. 116
4.6 Ventilation Blocks	p. 125
4.7 Little's Formula	p. 126
4.8 Poisson Process and the Exponential Distribution	p. 127
4.9 Cooling	p. 132
4.9.1 Lumped-temperature Model	p. 132
4.9.2 Heat Flow into a Semi-infinite Medium	p. 138
4.10 CFD Simulations	p. 141
4.10.1 High-pressure Die Casting	p. 142
4.10.2 Gravity Sand Casting	p. 152
5 Quality Control	p. 157
5.1 Basic Concepts of Quality Control	p. 157
5.2 Definition of Quality	p. 158
5.3 Definition of Control	p. 158
5.4 Statistical Process Control	p. 159
5.5 Tabular Summarization of Data	p. 160
5.6 Numerical Data Summarization	p. 160
5.6.1 Normal Probability Distribution	p. 161
5.6.2 Poisson Probability Distribution	p. 162
Appendix	p. 165
A.1 Unit Conversions	p. 165
A.2 Prefixes	p. 171
References	p. 173
Index	p. 175

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Table of Contents