首页|Failure analysis of a clutch wheel for wind turbines with the use of casting process simulation
Failure analysis of a clutch wheel for wind turbines with the use of casting process simulation
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NSTL
Elsevier
? 2022 The AuthorsProduction of high-quality and high-grade casts at the lowest possible cost is a priority of every foundry. Innovation and optimization of the currently applied production processes is a necessary step to achieving such a goal. Costly and long experiments performed in real foundries may be replaced with numerical simulations, as they provide reliable representation of the casting process using the computer technology. A detailed analysis of simulation results facilitates forecasting various risks that might negatively affect the quality of produced casts, and hence the quality of the entire production process. The present article discusses the effects of adjustments to the design of a gating system on the quality of a cast made of EN-GJS-500-7 ductile cast iron, which is used as a clutch wheel in turbines in wind power plants. During the production of the cast, two models of the gating system were created in Solid Works CAD software. The gating systems were validated using NovaFlow&Solid casting simulation software. The modification of the gating system design resulted in a reduced amount of liquid metal used for casting, which has significant economic effects in the mass production. Eight simulations of the designed gating systems were carried out. The main purpose of the simulations was to determine the mesh density as well as the casting and solidification conditions so that they are as close as possible to the real conditions in a foundry. Subsequently, the gating system was modified with the result of eliminating defects in the cast that occur during the solidification process as well as increasing the utilization of liquid metal.
NSTL
Elsevier
