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Optimal design of investment casting system for toothed chain joint: computer simulations and experimental verification

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Abstract

The toothed chain joint is a major component in heavy lifting equipment. They are usually fabricated using casting; however, residual casting defects in the joint tend to reduce mechanical strength and can lead to crack formation and creep following long-term usage. They also pose a safety hazard. In this study, numerical simulation was used to optimize the investment casting parameters for toothed chain joints of SNCM220 alloy. Optimization was based on predictions of cavity shrinkage, as determined using the retained melt modulus and probabilistic defect parameter, and porosity defects, estimated using the combined defect parameter-Niyama criterion. Preliminary simulation and experiment results were used to guide the establishment of two casting schemes: CaseA (reducing the length of the runner and removing the auxiliary inlets on both sides) and CaseB (increasing the number of inlets). Further simulations were conducted wherein the runner was covered with cotton insulation (6-mm thick). Virtual thermo-dynamical sensors were also used to determine the rate and direction of solidification in the mold cavity. Under nondestructive testing based on X-ray analysis, the investment castings fabricated under optimal conditions exhibited none of the detrimental defects commonly associated with this type of casting.

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Acknowledgments

The authors gratefully acknowledge the support provided for this research by Hei Full Industrial Co., LTD, Taiwan, for their assistance in the casting experiments of toothed chain joints.

Funding

This study received financial support from the Ministry of Science and Technology, R.O.C. under grants MOST 108-2221-E-224-034 and MOST 107-2622-E-224-013-CC3.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Yunlin University of Science and Technology, Douliu, Yunlin, 64002, Taiwan

    Pei-Hsing Huang & Chin-Yi Cheng

  2. Department of Mechanical Engineering, National Pingtung University of Science and Technology, Neipu, Pingtung, 912, Taiwan

    Wei-Ju Huang & Chuen-Shii Chou

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  1. Pei-Hsing Huang
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  2. Chin-Yi Cheng
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  3. Wei-Ju Huang
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  4. Chuen-Shii Chou
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Correspondence to Chuen-Shii Chou.

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Huang, PH., Cheng, CY., Huang, WJ. et al. Optimal design of investment casting system for toothed chain joint: computer simulations and experimental verification. Int J Adv Manuf Technol 106, 1931–1943 (2020). https://doi.org/10.1007/s00170-019-04765-0

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  • DOI: https://doi.org/10.1007/s00170-019-04765-0

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