Compared with the conventional casting process, digital pattern-less casting technology has many advantages such as good machining accuracy, a short processing cycle, and low production cost. It is a new rapid manufac...Compared with the conventional casting process, digital pattern-less casting technology has many advantages such as good machining accuracy, a short processing cycle, and low production cost. It is a new rapid manufacturing technology for castings, integrated with CAD/CAM, casting, CNC machining and many other advanced technologies. With this digital casting technology, no pattern is needed for making molds; it is precise, f lexible, and green. Usually, art castings have complex structures and are made in small batches or even made in a single-piece, especially for large-sized art castings. So it has the shortcomings of high cost, low eff iciency and long time for making a pattern to produce art castings with the conventional casting processes. However, the digital pattern-less casting technology can be applied to fabricate art castings, since it can greatly shorten the manufacturing cycle and lower the production cost, thus having a very good prospect. In this study, based on the digital pattern-less casting technology, a plaque casting with artistic Chinese characters(a Chinese poem) was designed and manufactured, and the production process was demonstrated in detail.展开更多
With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of...With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of the digital management aspect in precision casting enterprises, and puts forward three corresponding techniques. They are: the production process tracking card technology based on the main-sub card mode; the workshop site production process processing technology based on the barcode; and the equipment data integration technology. Then, this paper discusses in detail the principle, application and effect of these technologies; to provide the reference for enterprises to move towards digital casting and intelligent casting.展开更多
The copper disc casting machine is core equipment for producing copper anode plates in the copper metallurgy industry.The copper disc casting machine casting package motion curve(CPMC) is significant for precise casti...The copper disc casting machine is core equipment for producing copper anode plates in the copper metallurgy industry.The copper disc casting machine casting package motion curve(CPMC) is significant for precise casting and efficient production.However,the lack of exact casting modeling and real-time simulation information severely restricts dynamic CPMC optimization.To this end,a liquid copper droplet model describes the casting package copper flow pattern in the casting process.Furthermore,a CPMC optimization model is proposed for the first time.On top of this,a digital twin dual closed-loop self-optimization application framework(DT-DCS) is constructed for optimizing the copper disc casting process to achieve self-optimization of the CPMC and closed-loop feedback of manufacturing information during the casting process.Finally,a case study is carried out based on the proposed methods in the industrial field.展开更多
Casting blast can greatly reduce the stripping cost and improve the production capacity of opencast coal mines. Key technologies including high bench blasting, inclined hole, millisecond blasting, pre-splitting blasti...Casting blast can greatly reduce the stripping cost and improve the production capacity of opencast coal mines. Key technologies including high bench blasting, inclined hole, millisecond blasting, pre-splitting blasting and casting blast parameters determination which have influence on the effect of casting blast have been researched with the combination of the ballistic theory and experience in mines. The integrated digital processing system of casting blast was developed in order to simplify the design process of casting blast, improve working efficiency and veracity of design result and comprehensively adopt the software programming method and the theory of casting blast. This system has achieved five functions, namely, the 3D visualization graphics management, the intelligent management of geological information, the intelligent design of casting blast, the analysis and prediction of the blasting effect and the automatic output of the design results. Long-term application in opencast coal mines has shown that research results can not only reduce the specific explosive consumption and improve the blasting effect, but also have high value of popularization and application.展开更多
A complete and detail method is described to get digitally reconstructed radiographs （DRRs）. Casting rays to traverse CT images, computing CT values of resample points by interpolation, then converting CT value to i...A complete and detail method is described to get digitally reconstructed radiographs （DRRs）. Casting rays to traverse CT images, computing CT values of resample points by interpolation, then converting CT value to its attenuation coefficient by using simplified segment function. Finally, DRRs enhancement is made to get the better display of region of interest （ROI）, and a new way is adopted to adjust the customization coefficient. The experimental results show that the proposed method is effective in generating the satisfied DRRs.展开更多
Six specimens of fused cast AZS 33#material were taken as samples,and their chemical compositions and physical properties（ initial separating temperature o glass phase,corrosion amount in 24 h,glass phase seepage,and...Six specimens of fused cast AZS 33#material were taken as samples,and their chemical compositions and physical properties（ initial separating temperature o glass phase,corrosion amount in 24 h,glass phase seepage,and bulk density） were tested; low powered backscattered electron images of the samples（ three for each sample） were taken by a scanning electronic microscope with a reinforced backscattering probe. Then,firstly,the images were processed,and the phase compositions（relative contents of pores,matrix,alumina- zirconia eutectoid and primary baddeleyite） of the samples were obtained by counting. Secondly,the correlation coefficients of all parameters were calculated; indistinctive coefficients and unimportant variables were eliminated by F- test. Thirdly,the roadmap of the parameters was established and explained according to professiona knowledge.展开更多
The tensile response, the low cycle fatigue （LCF） resistance, and the creep behavior of an aluminum （A1） cast alloy are studied at ambient and elevated temperatures. A non-contact real-time optical extensometer ba...The tensile response, the low cycle fatigue （LCF） resistance, and the creep behavior of an aluminum （A1） cast alloy are studied at ambient and elevated temperatures. A non-contact real-time optical extensometer based on the digital image correlation （DIC） is developed to achieve strain measurements without damage to the specimen. The optical extensometer is validated and used to monitor dynamic strains during the mechanical experiments. Results show that Young＇s modulus of the cast alloy decreases with the increasing temperature, and the percentage elongation to fracture at 100 ℃ is the lowest over the temperature range evaluated from 25 ℃ to 300 ℃. In the LCF test, the fatigue strength coefficient decreases, whereas the fatigue strength exponent increases with the rising temperature. The fatigue ductility at 100 ℃. As expected, the resistance to and changes from 200 ℃ to 300 ℃. coefficient and exponent reach maximum values creep decreases with the increasing temperature展开更多
针对压铸系统缺乏实时质量反馈导致废品剔除滞后的问题,以电机外水套压铸系统为研究对象,提出一种基于遗传算法优化反向传播神经网络(genetic algorithm back propagation,GABP)的铸件质量预测方法。通过分析模具温度控制机理,利用模温...针对压铸系统缺乏实时质量反馈导致废品剔除滞后的问题,以电机外水套压铸系统为研究对象,提出一种基于遗传算法优化反向传播神经网络(genetic algorithm back propagation,GABP)的铸件质量预测方法。通过分析模具温度控制机理,利用模温机进油口温度参数间接表征模具温度变化趋势,并结合三阶傅里叶级数对温度数据进行曲线拟合,表征了一个压铸周期内温度参数的动态变化特征。基于构建的三阶傅里叶级数温度样本数据,训练GABP神经网络模型,构建了压铸件质量预测模型,并通过遗传算法对反向传播神经网络的权值与阈值进行优化,同时将铸件质量预测结果嵌入到压铸系统数字孪生模型,依此对压铸件的铸件质量进行实时监测和反馈。展开更多
基金financially supported by the National Natural Science Foundation of China(No.51105257)
文摘Compared with the conventional casting process, digital pattern-less casting technology has many advantages such as good machining accuracy, a short processing cycle, and low production cost. It is a new rapid manufacturing technology for castings, integrated with CAD/CAM, casting, CNC machining and many other advanced technologies. With this digital casting technology, no pattern is needed for making molds; it is precise, f lexible, and green. Usually, art castings have complex structures and are made in small batches or even made in a single-piece, especially for large-sized art castings. So it has the shortcomings of high cost, low eff iciency and long time for making a pattern to produce art castings with the conventional casting processes. However, the digital pattern-less casting technology can be applied to fabricate art castings, since it can greatly shorten the manufacturing cycle and lower the production cost, thus having a very good prospect. In this study, based on the digital pattern-less casting technology, a plaque casting with artistic Chinese characters(a Chinese poem) was designed and manufactured, and the production process was demonstrated in detail.
基金financially supported by the National Science&Technology Key Projects of Numerical Control(2012ZX04012-011)National High-tech R&D Program(863 program)(2013031003)
文摘With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of the digital management aspect in precision casting enterprises, and puts forward three corresponding techniques. They are: the production process tracking card technology based on the main-sub card mode; the workshop site production process processing technology based on the barcode; and the equipment data integration technology. Then, this paper discusses in detail the principle, application and effect of these technologies; to provide the reference for enterprises to move towards digital casting and intelligent casting.
基金supported in part by the National Major Scientific Research Equipment of China (61927803)the National Natural Science Foundation of China Basic Science Center Project (61988101)+1 种基金Science and Technology Innovation Program of Hunan Province (2021RC4054)the China Postdoctoral Science Foundation (2021M691681)。
文摘The copper disc casting machine is core equipment for producing copper anode plates in the copper metallurgy industry.The copper disc casting machine casting package motion curve(CPMC) is significant for precise casting and efficient production.However,the lack of exact casting modeling and real-time simulation information severely restricts dynamic CPMC optimization.To this end,a liquid copper droplet model describes the casting package copper flow pattern in the casting process.Furthermore,a CPMC optimization model is proposed for the first time.On top of this,a digital twin dual closed-loop self-optimization application framework(DT-DCS) is constructed for optimizing the copper disc casting process to achieve self-optimization of the CPMC and closed-loop feedback of manufacturing information during the casting process.Finally,a case study is carried out based on the proposed methods in the industrial field.
基金Project supported by the Fundamental Research Funds for the Central Universities,China
文摘Casting blast can greatly reduce the stripping cost and improve the production capacity of opencast coal mines. Key technologies including high bench blasting, inclined hole, millisecond blasting, pre-splitting blasting and casting blast parameters determination which have influence on the effect of casting blast have been researched with the combination of the ballistic theory and experience in mines. The integrated digital processing system of casting blast was developed in order to simplify the design process of casting blast, improve working efficiency and veracity of design result and comprehensively adopt the software programming method and the theory of casting blast. This system has achieved five functions, namely, the 3D visualization graphics management, the intelligent management of geological information, the intelligent design of casting blast, the analysis and prediction of the blasting effect and the automatic output of the design results. Long-term application in opencast coal mines has shown that research results can not only reduce the specific explosive consumption and improve the blasting effect, but also have high value of popularization and application.
基金Support by Natural Science Foundation of Yunnan Province (2008 C0013R)
文摘A complete and detail method is described to get digitally reconstructed radiographs （DRRs）. Casting rays to traverse CT images, computing CT values of resample points by interpolation, then converting CT value to its attenuation coefficient by using simplified segment function. Finally, DRRs enhancement is made to get the better display of region of interest （ROI）, and a new way is adopted to adjust the customization coefficient. The experimental results show that the proposed method is effective in generating the satisfied DRRs.
基金funded by "Green Manufacturing Processes and Equipment",a Key Project of the National Eleventh - Five Year Research Project of China (2006BAF02A26)
文摘Six specimens of fused cast AZS 33#material were taken as samples,and their chemical compositions and physical properties（ initial separating temperature o glass phase,corrosion amount in 24 h,glass phase seepage,and bulk density） were tested; low powered backscattered electron images of the samples（ three for each sample） were taken by a scanning electronic microscope with a reinforced backscattering probe. Then,firstly,the images were processed,and the phase compositions（relative contents of pores,matrix,alumina- zirconia eutectoid and primary baddeleyite） of the samples were obtained by counting. Secondly,the correlation coefficients of all parameters were calculated; indistinctive coefficients and unimportant variables were eliminated by F- test. Thirdly,the roadmap of the parameters was established and explained according to professiona knowledge.
基金supported by the National Natural Science Foundation of China(Nos.11372173,11672347,and 11727804)the Science and Technology Development Foundation of Shanghai Automobile Industry(No.1514)
文摘The tensile response, the low cycle fatigue （LCF） resistance, and the creep behavior of an aluminum （A1） cast alloy are studied at ambient and elevated temperatures. A non-contact real-time optical extensometer based on the digital image correlation （DIC） is developed to achieve strain measurements without damage to the specimen. The optical extensometer is validated and used to monitor dynamic strains during the mechanical experiments. Results show that Young＇s modulus of the cast alloy decreases with the increasing temperature, and the percentage elongation to fracture at 100 ℃ is the lowest over the temperature range evaluated from 25 ℃ to 300 ℃. In the LCF test, the fatigue strength coefficient decreases, whereas the fatigue strength exponent increases with the rising temperature. The fatigue ductility at 100 ℃. As expected, the resistance to and changes from 200 ℃ to 300 ℃. coefficient and exponent reach maximum values creep decreases with the increasing temperature
文摘针对压铸系统缺乏实时质量反馈导致废品剔除滞后的问题,以电机外水套压铸系统为研究对象,提出一种基于遗传算法优化反向传播神经网络(genetic algorithm back propagation,GABP)的铸件质量预测方法。通过分析模具温度控制机理,利用模温机进油口温度参数间接表征模具温度变化趋势,并结合三阶傅里叶级数对温度数据进行曲线拟合,表征了一个压铸周期内温度参数的动态变化特征。基于构建的三阶傅里叶级数温度样本数据,训练GABP神经网络模型,构建了压铸件质量预测模型,并通过遗传算法对反向传播神经网络的权值与阈值进行优化,同时将铸件质量预测结果嵌入到压铸系统数字孪生模型,依此对压铸件的铸件质量进行实时监测和反馈。
