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Simulation based process design approach for manufacturing of light-weight cast components
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.ORCID iD: 0000-0003-3086-0901
Swerea SWECAST AB, Sweden.
TPC Components AB, Sweden.
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.ORCID iD: 0000-0002-7816-1213
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2017 (English)Conference paper, Published paper (Refereed)
Abstract [en]

Weight reduction of engineering systems, especially for turbines is desirable due to global requirements for lower fuel consumption and emissions. The resulting design modifications by system manufacturers place demands on foundries to be able to cast thin-walled and complex hot-gas-path components with consistent quality and shorter lead times. The ability to cast components in thinner sections can result in overall weight reduction of turbines. Casting of thin-sections is challenging due to faster solidification and is sensitive to variation in critical process parameters in the foundry. The aim of this work is to develop a framework using design of experiments and simulation to develop a robust casting process as an alternative to costly trial and error that are frequently applied. The Distance based response surface method (RSM) is used to make a Design of experiments (DoE). By using a simulation tool that replicates the process conditions, the test iterations were simulated and regression analysis of the shrinkage and misrun values predicted by the model was performed to determine the effect of casting conditions on defect formation. The optimization of the process conditions was done by adjusting ranges and targets for the response and optimal conditions were proposed for casting.

Place, publisher, year, edition, pages
2017.
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:mdh:diva-38770OAI: oai:DiVA.org:mdh-38770DiVA, id: diva2:1186072
Conference
LIGHTer International Conference 2017, 22-23 November 2017, Gothenburg, Sweden
Available from: 2018-02-27 Created: 2018-02-27 Last updated: 2018-04-12Bibliographically approved

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Raza, MohsinFagerström, Björn

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CiteExportLink to record
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Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
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Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf