Engineering computing and data-driven for gating system design in investment casting
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ORIGINAL ARTICLE
Engineering computing and data-driven for gating system design in investment casting Jiangping Yu 1,2 & Donghong Wang 1,4 & Dayong Li 2 & Ding Tang 2 & Xin Hao 3,4 & Shixin Tan 3 & Da Shu 1 & Yinghong Peng 2 & Baode Sun 1 Received: 12 April 2020 / Accepted: 22 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The geometrical shape of the gating system and the casting process are vital to the occurrence of shrinkage porosity, and the effects of their combination directly determine the desired high-quality casting. Casting simulation plays a significant role in the deduction of the trial and error method for gating system design in investment casting, which is time-consuming. A breakthrough in optimization design often requires a comprehensive understanding of the geometrical structure of the gating system and the complex process parameter to generate a novel data-driven framework that improves the higher quality of casting and reduces the period of design. This paper proposed a data-driven framework to investigate the optimal gating system design integrated with complex casting processes through RBF optimization algorithm with the target of porosity-free casting as well as high casting yield percentage. The results demonstrate that the optimization of the gating design is more inspiring with high accuracy and high efficiency, and the casting yield is increased by 14.91%. Furthermore, the verification between simulation and experiments shows good agreement. The demonstrated data-driven approach is feasible and effective and can be extended not only incorporating the geometrical structure of the gating system and casting processes in investment casting optimization but also other potential types of casting design. Keywords Investment casting . Shrinkage porosity . Casting yield . Data-driven . Engineering computing . Optimization
1 Introduction Investment casting is extensively applied to produce highquality products, especially in the applications of complex thin-walled parts. The gating design is vital to the quality of casting components as it is used to guide the metal into the
* Donghong Wang [email protected] 1
Shanghai Key Laboratory of Advanced High Temperature Materials and Precision Forming, State Key Laboratory of Metal Matrix Composites, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2
State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, 800 Dongchuan RD, Minhang District, Shanghai 200240, China
3
China Aircraft Southern Industry Co., Ltd, Changsha 410000, Hunan, China
4
State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710000, China
mold cavity, compensating for the shrinkage when the metal solidifies. Generally, the design of a gating system is based on the engineering experience and empirical rules accumulated for decades and then carried out on numerous trial and error me
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