A Study on Stress Analysis of Aluminum Alloy Solidified in Metallic Molds

Volume: 10 | Issue: 02 | Year 2024 | Subscription
International Journal of Manufacturing and Materials Processing
Received Date: 10/29/2024
Acceptance Date: 11/14/2024
Published On: 2024-11-22
First Page: 10
Last Page: 15

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By: Satyanarayan ., Chiranth H.S, Paigambar Nadaf, Akhil Sharma, Veerabhadrappa Algur, Kumarswamy M.C., and Kusammanavar Basavaraj

1. Head Professor, Department of Mechanical Engineering, Alva’s Institute of Engineering and Technology, Moodubidire, Mangaluru, Karnataka, India
2-4,7. Student, Department of Mechanical Engineering, Alva’s Institute of Engineering and Technology, Moodubidire, Mangaluru, Karnataka, India
5. Associate Professor, Department of Mechanical Engineering, Rao Bahadur Y Mahabaleswarappa Engineering College, Ballari, Karnataka, India
6. Assistant Professor, Department of Mechanical Engineering, Rao Bahadur Y Mahabaleswarappa Engineering College, Ballari, Karnataka, India

Abstract

Abstract

The casting technique is regarded as the primary manufacturing process. It has several process parameters that affect the cast structure. Mold geometry is considered one of the most important metal parameters to cast. In the current work, the influence of mold geometries on mechanical properties (deformation and stress concentration) of liquid Aluminum alloy solidified in the steel mold is assessed using ANSYS simulation software. Molds were subject to a 0.010KPa tensile pressure to observe the deformation along three directions (X, Y and Z axis). Simulation results exhibited  that liquid alloy solidified in mold of circular geometry deformed non-uniformly whereas alloy cooled in hexagonal mold deformed uniformly. Alloys cooled in square mold showed intermediate behavior in terms of deformation. The load-carrying capacity of casted hexagonal specimens was found to be better than square and circular specimens. Casted circular specimens indicate very high stress concentration at the edges. However, the hexagonal-shaped casted specimen showed uniformly distributed stress concentration compared to circular and square-shaped casted specimens.

Keywords: Metal mold, pure metal, mechanical property, simulation, stress concentration

REFERENCES

  1. Prabhu KN, Suresha KM. Effect of superheat, mold, and casting materials on the metal/mold interfacial heat transfer during solidification in graphite-lined permanent molds. J Mater Eng Perform. 2004;13.5:619–626. doi: 10.1361/10599490420647.
  2. Available at http://www.themetalcasting.com/obtaining-casting-geometry.html [Accessed on December 2021].
  3. Wu C-D, Fang T-H, Chiang C-C, Kuo L-M. Effect of mold geometry on nanoformed aluminum films investigated using molecular dynamics simulations. Computational materials science 2013;74:17–22. doi: 10.1016/j.commatsci.2013.03.003.
  4. Gupta A, Singh RK, Paul A, Kumar S. Effect of mould geometry, coating, and plate thickness on the thermal profile of continuous casting moulds. J South Afr Inst Min Metall. 2018;118(5):505–513. doi: 10.17159/2411-9717/2018/v118n5a7.
  5. Park JK, Samarasekera IV, Thomas BG, Yoon US. Thermal and mechanical behavior of copper molds during thin-slab casting (I): Plant trial and mathematical modeling. Metall Mater Trans B.  2002;33(3):425–436. doi: 10.1007/s11663-002-0054-x.
  6. Gwyn M. Casting design and geometry. In: Srinath Viswanathan, Diran Apelian, Raymond J. Donahue, Babu DasGupta, Michael Gywn, John L. Jorstad, Raymond W. Monroe, Mahi Sahoo, Thomas E. Prucha, Daniel Twarog, editor. ASM Handbook. 2008;15. doi: 10.31399/Asm.Hb.V15.A0009020.
  7. Prasanna SY, Sha M, Kumar K, Shreedhar B, Kumar V, Satyanarayan. Effect of casting moulds on tribological properties of Al-Sn alloy. IJRTI. 2019;4(5):15–18.
  8. Bhat J, Satyanarayan. Effect of cooling medium on microstructure, impact and hardness properties of Al–15Sn alloy. Trans Indian Inst Met. 2019;72:1941–1947. doi: 10.1007/s12666-019-01670-8.
  9. Prabhu KN, Deshapande P, Satyanarayan. Effect of cooling rate during solidification of Sn–9Zn lead-free solder alloy on its microstructure, tensile strength and ductile–brittle transition temperature. Mater Sci Eng A. 2012;533:64–70.
  10. Satyanarayan, Raju R, Algur V, MC KS, A J, Basavaraja K. An investigation on effects of modes of cooling on mechanical property of Sn-Cu alloy. 2023. doi: 10.21203/rs.3.rs-2943612/v1. Available at https://www.researchgate.net/publication/370906438_An_Investigation_on_
    Effects_of_Modes_of_Cooling_on_Mechanical_Property_of_Sn-Cu_Alloy/fulltext/6468d24966
    b4cb4f73c322b3/An-Investigation-on-Effects-of-Modes-of-Cooling-on-Mechanical-Property-of-Sn-Cu-Alloy.pdf

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Citation:

How to cite this article: Satyanarayan ., Chiranth H.S, Paigambar Nadaf, Akhil Sharma, Veerabhadrappa Algur, Kumarswamy M.C., and Kusammanavar Basavaraj, A Study on Stress Analysis of Aluminum Alloy Solidified in Metallic Molds. International Journal of Manufacturing and Materials Processing. 2024; 10(02): 10-15p.

How to cite this URL: Satyanarayan ., Chiranth H.S, Paigambar Nadaf, Akhil Sharma, Veerabhadrappa Algur, Kumarswamy M.C., and Kusammanavar Basavaraj, A Study on Stress Analysis of Aluminum Alloy Solidified in Metallic Molds. International Journal of Manufacturing and Materials Processing. 2024; 10(02): 10-15p. Available from:https://journalspub.com/publication/ijmmp/article=16089

Refrences:

1.
Prabhu KN, Suresha KM. Effect of superheat, mold, and casting materials on the metal/mold interfacial heat transfer during solidification in graphite-lined permanent molds. J Mater Eng Perform. 2004;13.5:619–626. doi: 10.1361/10599490420647.
2.
Available at http://www.themetalcasting.com/obtaining-casting-geometry.html [Accessed on December 2021].
3.
Wu C-D, Fang T-H, Chiang C-C, Kuo L-M. Effect of mold geometry on nanoformed aluminum films investigated using molecular dynamics simulations. Computational materials science 2013;74:17–22. doi: 10.1016/j.commatsci.2013.03.003.
4.
Gupta A, Singh RK, Paul A, Kumar S. Effect of mould geometry, coating, and plate thickness on the thermal profile of continuous casting moulds. J South Afr Inst Min Metall. 2018;118(5):505–513. doi: 10.17159/2411-9717/2018/v118n5a7.
5.
Park JK, Samarasekera IV, Thomas BG, Yoon US. Thermal and mechanical behavior of copper molds during thin-slab casting (I): Plant trial and mathematical modeling. Metall Mater Trans B. 2002;33(3):425–436. doi: 10.1007/s11663-002-0054-x.
6.
Gwyn M. Casting design and geometry. In: Srinath Viswanathan, Diran Apelian, Raymond J. Donahue, Babu DasGupta, Michael Gywn, John L. Jorstad, Raymond W. Monroe, Mahi Sahoo, Thomas E. Prucha, Daniel Twarog, editor. ASM Handbook. 2008;15. doi: 10.31399/Asm.Hb.V15.A0009020.

7.
Prasanna SY, Sha M, Kumar K, Shreedhar B, Kumar V, Satyanarayan. Effect of casting moulds on tribological properties of Al-Sn alloy. IJRTI. 2019;4(5):15–18.
8.
Bhat J, Satyanarayan. Effect of cooling medium on microstructure, impact and hardness properties of Al–15Sn alloy. Trans Indian Inst Met. 2019;72:1941–1947. doi: 10.1007/s12666-019-01670-8.
9.
Prabhu KN, Deshapande P, Satyanarayan. Effect of cooling rate during solidification of Sn–9Zn lead-free solder alloy on its microstructure, tensile strength and ductile–brittle transition temperature. Mater Sci Eng A. 2012;533:64–70.
10.
Satyanarayan, Raju R, Algur V, MC KS, A J, Basavaraja K. An investigation on effects of modes of cooling on mechanical property of Sn-Cu alloy. 2023. doi: 10.21203/rs.3.rs-2943612/v1. Available at https://www.researchgate.net/publication/370906438_An_Investigation_on_ Effects_of_Modes_of_Cooling_on_Mechanical_Property_of_Sn-Cu_Alloy/fulltext/6468d24966 b4cb4f73c322b3/An-Investigation-on-Effects-of-Modes-of-Cooling-on-Mechanical-Property-of-Sn-Cu-Alloy.pdf

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