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COMPUTER SIMULATION AND LOW-COST OPTIMIZATION OF AN INVESTMENT BI-METAL CASTING PROCESS

by ZHOU, XINYU

Abstract (Summary)
Investment bi-metal casting is a newly developed casting process and is prone to have more defects. Process optimization based on a computer simulation model is critical to obtain high quality castings. To obtain an accurate defect prediction analytically in the bi-metal casting part relies on the full consideration of the entire physical phenomenon during the process. It is also important to reduce the simulation time cost of the optimization process in order to make it practically achievable. This dissertation first presents the methods to develop a representative computer simulation model of the investment bi-metal casting process to predict the existing defects, such as: cracks, porosity, cold shut, hot tearing, deformation, etc. The model has been validated by experimental data. Secondly, this dissertation presents an integrated low time cost approach to optimize the investment bi-metal casting process based on the computer simulation model. As a case study, by employing the integrated optimization technology, an investment bi-metal casting process of a Spiral Flight is optimized to obtain better process specifications. The Monte Carlo analysis of the original and optimal process shows a significant improvement of the casting result.
Bibliographical Information:

Advisor:

School:University of Cincinnati

School Location:USA - Ohio

Source Type:Master's Thesis

Keywords:investment bi metal casting process finite element method simulation response surface model optimization

ISBN:

Date of Publication:01/01/2005

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