EBOOK - Castings Practice - The Ten Rules of Castings (John Campbell) | Cộng đồng Kỹ thuật cơ điện Việt Nam EBOOKBKMT

CONTENTS:

Rule1. Achieveagoodquality melt 1

1.1 Background 1

1.2 Melting 3

1.3 Holding 3

1.4 Pouring 4

1.5 Melttreatments 5

1.5.1 Degassing 5

1.5.2 Additions 6

1.6 Filtration 7

1.6.1 Packedbeds 7

1.6.2 Alternativevarietiesof

filters 8

1.6.3 Practicalaspects 8

Rule2. Avoidturbulent entrainment(the

criticalvelocity requirement) 9

2.1 Maximumvelocity

requirement 10

2.2 The`no fall'requirement 13

2.3 Fillingsystemdesign 15

2.3.1 Gravitypouringof

open-topmoulds 15

2.3.2 Gravitypouringofclosed

moulds 16

2.3.3 Horizontaltransfer

casting 68

2.3.4 Counter-gravity 72

2.3.5 Surfacetensioncontrolled

filling 75

2.3.6 Inclusioncontrol:filters

andtraps 78

2.3.7 Practicalcalculationofthe

fillingsystem 93

Rule3. Avoidlaminar entrainmentofthe

surfacefilm (thenon-stopping,

non-reversingcondition) 102

3.1 Continuousexpansionofthe

meniscus 102

3.2 Arrestofverticalprogress 103

3.3 Waterfallflow 104

3.4 Horizontalstreamflow 104

3.5 Hesitationandreversal 106

Rule4. Avoidbubbledamage 108

4.1 Gravity-filledrunning

systems 111

4.2 Pumpedandlow-pressure filling

systems 112

Rule5. Avoidcoreblows 114

5.1 Background 114

5.2 Prevention 117

Rule6. Avoidshrinkagedamage 120

6.1 Feedingsystemsdesign

background 120

6.1.1 Gravityfeeding 123

6.1.2 Computermodellingof

feeding 124

6.1.3 Randomperturbationsto

feeding patterns 124

6.1.4 Dangersofsolid

feeding 125

6.1.5 Thenon-feedingrolesof

feeders 125

6.2 Thesevenfeeding rules 126

Rule1: Donotfeed 126

Rule2: Heat-transfer

requirement 127

Rule3: Mass-transfer

requirement 128

Rule4: Junction

requirement 132

Rule5: Feedpath

requirement 133

Rule6: Pressuregradient

requirement 138

Rule7: Pressure

requirement 140

6.3 Thenewfeedinglogic 142

6.3.1 Background 142

6.3.2 Thenewapproach 143

6.4 Activefeeding 145

6.5 Freezingsystemsdesign 146

6.5.1 Externalchills 147

6.5.2 Internalchills 149

6.5.3 Fins 150

Rule7.Avoidconvection damage 157

7.1 Convection:theacademic

background 157

7.2 Convection:theengineering

imperatives 157

7.3 Convectiondamageandcasting

sectionthickness 160

7.4 Counteringconvection 162

Rule8.Reducesegregationdamage 163

Rule9.Reduceresidualstress(the`no water

quench'requirement) 166

9.1 Introduction 166

9.2 Residualstressfrom casting 166

9.3 Residualstressfrom

quenching 167

9.4 Distortion 172

9.5 Heattreatmentdevelopments 173

9.6 Epilogue 174

Rule10.Providelocation points 175

10.1 Datums 175

10.2 Locationpoints 176

10.2.1 Rectilinearsystems 177

10.2.2 Cylindricalsystems 178

10.2.3 Trigonalsystems 179

10.2.4 Thin-walledboxes 179

10.3 Locationjigs 180

10.4 Clampingpoints 180

10.5 Moulddesign:thepractical

issues 181

10.6 Castingaccuracy 182

10.7 Toolingaccuracy 183

10.8 Mouldaccuracy 183

10.9 Summaryoffactors affecting

accuracy 186

10.10 Metrology 186

Appendix 188

The1.5factor 188

TheBernoulliequation 189

Rateofpourofsteelcastingsfroma

bottom-pourladle 191

Runningsystemcalculationrecord 191

Designmethodologyforinvestment

castings 194

References 195

Index 199

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