Skip to main content
SpringerLink
Log in

Research and Development of Gating and Riser Process Optimization Integrated System for Steel Casting

  • Technical Paper
  • Published:
International Journal of Metalcasting Aims and scope Submit manuscript

Abstract

With the development of high-speed computer technology, casting CAE and casting CAD effectively improve the design efficiency and accuracy of casting process. To achieve the rapid and convenient design of the casting process, the paper presents the framework of gating and riser process optimization integrated system, which realizes the integration of casting CAD, process optimization and casting CAE. The “passive” mode of traditional artificial experience is changed to the “active” mode of system intelligent optimization. The key technologies for the establishment of integrated systems are analyzed in detail. An integrated system of gating and riser process optimization for steel casting is successfully developed based on Open CASCADE kernel and wxWidgets. The process optimization process of gating system and riser system is given in detail by actual castings. The application results indicate that the integrated system can realize the process optimization of steel castings and provides new ideas and key technology for intelligent process design of steel castings.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31

Similar content being viewed by others

References

  1. S.F. Su, Casting manual—Volume 5—Casting process - 4th Edition (China Machine Press, Beijing, 2021)

  2. J. Campbell, Complete casting handbook—metal casting processes, metallurgy, techniques and design (Butterworth-Heinemann, Oxford, 2011)

    Google Scholar 

  3. S.H. Majidi, C. Beckermann, Effect of pouring conditions and gating system design on air entrainment during mold filling. Inter. Metalcast. 13, 255–272 (2019). https://doi.org/10.1007/s40962-018-0272-x

    Article  CAS  Google Scholar 

  4. N. Mahomed, H.A. Kleynhans, Reducing shrinkage porosity in high-performance steel castings: case of an ASME B16.34 gate valve body: part 1—analysis, techniques and experimental approach. Inter. Metalcast. 12, 919–926 (2018). https://doi.org/10.1007/s40962-018-0226-3

    Article  CAS  Google Scholar 

  5. N. Mahomed, H.A. Kleynhans, Reducing shrinkage porosity in high-performance steel castings: case of an ASME B16.34 gate valve body: part 2—simulation and experimental verification. Inter. Metalcast. 13, 463–472 (2019). https://doi.org/10.1007/s40962-018-0275-7

    Article  CAS  Google Scholar 

  6. K.D. Carlson, C. Beckermann, Prediction of shrinkage pore volume fraction using a dimensionless Niyama criterion. Metall. Mater. Trans. A 40(1), 163–175 (2009)

    Article  Google Scholar 

  7. Y. Takemoto, M. Mizumoto, K. Kinno, Internal porosity defects in ductile cast irons. Inter. Metalcast. 15, 916–929 (2021). https://doi.org/10.1007/s40962-020-00527-x

    Article  CAS  Google Scholar 

  8. J.X. Zhou, Current status and development trend of casting numerical simulation technology. Foundry 61(10), 1105–1115 (2012)

    Google Scholar 

  9. C.H. Lim, S.H. Cho, Y.C. Lee, J.K. Choi, Basic construction of intelligent expert system for riser design using database system and optimisation tools. Int. J. Cast Metals Res. 18(4), 195–201 (2005)

    Article  Google Scholar 

  10. R. Kumar, S. Madhu, K. Aravindh, V. Jayakumar, G. Bharathiraja, A. Muniappan, Casting design and simulation of gating system in rotary adaptor using procast software for defect minimization. Mater. Today Proc. 22(3), 799–805 (2020)

    Article  Google Scholar 

  11. https://www.magmasoft.cn/en/

  12. S.S. Gao, Computer technology and its application in foundry industry. Foundry 44(6), 31–38 (1995)

    Google Scholar 

  13. J.K. Hu, Research and development of engineering oriented CAD system for riser optimization design (Dalian University of Technology, Dalian, 2009)

    Google Scholar 

  14. J. Long, The development and research of common casting process 2D CAD system (Huazhong University of Science and Technology, Wuhan, 2014)

    Google Scholar 

  15. Y.L. Li, The research of casting process CAD system for aluminum alloy castings based on UG (Huazhong University of Science and Technology, Wuhan, 2019)

    Google Scholar 

  16. J. Zhou, T. Jing, Integration of CAD/CAE system for casting process design. Tsinghua Sci. Technol. 8(1), 117–120 (2003)

    Google Scholar 

  17. S.H. Yue, G.X. Wang, F. Yin, Y.X. Wang, J.B. Yang, Application of an integrated CAD/CAE/CAM system for die casting dies. J. Mater. Process. Tech. 139(1), 465–468 (2003)

    Article  Google Scholar 

  18. H.T. Tang, Research on the platform of digital casting process design and management (Huazhong University of Science and Technology, Wuhan, 2013)

    Google Scholar 

  19. X.D. Gong, D.M. Liao, T. Chen, J.X. Zhou, Y.J. Yin, Optimization of steel casting feeding system based on BP neural network and genetic algorithm. China Foundry. 13(3), 182–190 (2016)

    Article  Google Scholar 

  20. D. Liu, D.M. Liao, Y.L. Tang, T. Chen, The post-processing display and riser design for casting CAD/CAE integration system in UG environment. Foundry. 65(10), 980–983 (2016)

    Google Scholar 

  21. I. Matin, M. Hadzistevic, D. Vukelic, M. Potran, T. Brajlih, Development of an expert system for the simulation model for casting metal substructure of a metal-ceramic crown design. Comput. Meth. Prog. Biomed. 146, 27–35 (2017)

    Article  Google Scholar 

  22. N. Dučić, R. Slavković, I. Milićević, Ž Ćojbašić, S. Manasijević, R. Radiša, Optimization of the gating system for sand casting using genetic algorithm. Int. J. Met. 11(2), 255–265 (2017)

    Google Scholar 

  23. N. Dučić, A. Jovičić, R. Radiša, S. Manasijević, R. Slavković, D. Radović, Application of CAD/CAE/CAM systems in permanent-mold casting improvement. Teh. Vjesn 27(6), 2077–2082 (2020)

    Google Scholar 

  24. https://www.opencascade.com/

  25. H. Ding, Z. Wang, Development and research of CAD system based on OpenCASCADE platform. J Southwest Univ. Sci. Technol. 29(2), 72–76 (2014)

    Google Scholar 

  26. Z. Liu, B. Sun, Research on 3D sheet metal design system based on OpenCASCADE modeling kernel. Machi. Design Manuf. 8, 92–94 (2012)

    Google Scholar 

  27. T. Wang, Y.J. Yin, J.X. Zhou, X. Shen, M. Wang, Optimal riser design method based on geometric reasoning method and fruit fly optimization algorithm in CAD. Int. J. Adv. Manuf. Tech. 96(1–4), 53–65 (2018)

    Article  Google Scholar 

  28. J.X. Zhou, Q. Zhou, T. Chen, Y.J. Yin, X. Shen, Computation of feed-path based on temperature gradient method. Mater. Res. Innov. 19(S5), 811–816 (2015)

    Google Scholar 

  29. J.X. Zhou, M. Wang, Y.J. Yin, X. Shen, X. Chen, W. Li, D.Q. Zhang, Feed paths and hot spots computation based on a time gradient method in casting. Int. J. Adv. Manuf. Tech. 93(1–4), 261–272 (2017)

    Article  Google Scholar 

  30. Q. Zhou, T. Wang, X. Shen, J.X. Zhou, Three-dimensional feed path computation of steel casting based on time gradient method. Spec. Cast. Nonferrous Alloys. 42(2), 158–161 (2022)

    Google Scholar 

  31. T. Wang, X. Shen, J.X. Zhou, Y.J. Yin, X.Y. Ji, Q. Zhou, Optimal gating system design of steel casting by fruit fly optimization algorithm based on casting simulation technology. Int. J. Met. 13(3), 561–570 (2019)

    CAS  Google Scholar 

  32. L.H. Yang, Software development of dynamic signal analyzer based on wxWidgets (University of Electronic Science and Technology, Chengdu, 2015)

    Google Scholar 

Download references

Acknowledgements

This research was financially supported by the State Key Laboratory of Materials Processing and Die and Mold Technology, Huazhong University of Science and Technology (P2022-012, P2022-018), Key Research and Development Program Project of Hubei Provincial (2022BAD102), and Science and Technology Research Project of Department of Education of Hubei Province (B2022026).

Author information

Authors and Affiliations

  1. Key Laboratory of Metallurgical Equipment and Control Technology, Ministry of Education, Wuhan University of Science and Technology, Wuhan, 430081, China

    Tong Wang, Lei Wang, Zelin Zhang, Huan Zhang & Xuhui Xia

  2. Precision Manufacturing Institute, Wuhan University of Science and Technology, Wuhan, 430081, China

    Tong Wang, Lei Wang, Zelin Zhang, Huan Zhang & Xuhui Xia

  3. State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Jianxin Zhou

Authors
  1. Tong Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jianxin Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Lei Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zelin Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Huan Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Xuhui Xia
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Huan Zhang or Xuhui Xia.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

This paper is an invited submission to IJMC selected from presentations at the 74th World Foundry Congress, held October 16 to 20, 2022, in Busan, Korea, and has been expanded from the original presentation.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, T., Zhou, J., Wang, L. et al. Research and Development of Gating and Riser Process Optimization Integrated System for Steel Casting. Inter Metalcast 17, 2452–2468 (2023). https://doi.org/10.1007/s40962-023-00982-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40962-023-00982-2

Keywords

Search

Navigation