Numerical optimization of the taper a vertically cast plate

Brno University of Technology, Faculty of Mechanical Engineering, Czech Republic

Abstract

The temperature field of the studied plate was analyzed with different angles of widening in its cross section (in the range from 0° to 4.4°). From the inclined side, the plate was either insulated or uninsulated. Plastizol was used as an insulator. An uninsulated plate has a calculated optimum angular expansion of 3°. A widening of 2° is the minimum angle at which internal defects (e.g. shrinkage voids) begin to disappear. The insulated plate has an optimum angle of 2°. Using numerical calculations, it is possible to predict that after crystallization without insulation, the plate itself with a widening of 3° will have the same internal quality as a widening of 2° with insulation. The knowledge gained from this study can lead to a reduction in the volume of liquid metal used and also to a reduction in machining costs. These research results have already been successfully applied to the design of the technology for casting nodular cast iron cylinder liners.