Implementing CFD modelling to address defect formation in core injection moulding

Stefano Cademartori; Nicholas Humphreys; Jean Christophe Gebelin; Jeffery Brooks

doi:10.1007/978-3-319-72059-3_20

Implementing CFD modelling to address defect formation in core injection moulding

Stefano Cademartori^*, Nicholas Humphreys, Jean Christophe Gebelin, Jeffery Brooks

^*Corresponding author for this work

Metallurgy and Materials

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

Abstract

Ceramic cores are used in casting processes to create complex internal shapes within the final component. The work presented here uses Computational Fluid Dynamics (CFD) analysis to predict the filling and solidification behaviour of ceramic core material during the Ceramic Injection Moulding (CIM) process in the large, complex geometries now typical of modern cores. The aim of the study is to develop a predictive capability to identify key defects in the core that might otherwise only be observed after a number of expensive manufacturing processes. Manufacturing trials using short shots have been carried out in order to validate the transient flow patterns of the paste; this has highlighted the occurrence of jetting, weld lines and flow defects that are highly dependent on the injection parameters and runner designs employed. Analysis of the modelled solidification, shear rates, stagnation points and phase migration has driven die and process optimisation in a production environment.

Original language	English
Title of host publication	CFD Modeling and Simulation in Materials Processing 2018
Publisher	Springer
Pages	213-222
Number of pages	10
ISBN (Electronic)	9783319720593
ISBN (Print)	9783319720586
DOIs	https://doi.org/10.1007/978-3-319-72059-3_20
Publication status	Published - 13 Jan 2018
Event	International Symposium on CFD Modeling and Simulation in Materials Processing, 2018 - Phoenix, United States Duration: 11 Mar 2018 → 15 Mar 2018

Publication series

Name	Minerals, Metals and Materials Series
Volume	Part F3
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	International Symposium on CFD Modeling and Simulation in Materials Processing, 2018
Country/Territory	United States
City	Phoenix
Period	11/03/18 → 15/03/18

Keywords

Ceramic
CFD
CIM
Defect
Injection moulding
Process
Simulation
StarCCM+

ASJC Scopus subject areas

Electronic, Optical and Magnetic Materials
Energy Engineering and Power Technology
Mechanics of Materials
Metals and Alloys
Materials Chemistry

Access to Document

10.1007/978-3-319-72059-3_20Licence: None: All rights reserved

https://link.springer.com/chapter/10.1007%2F978-3-319-72059-3_20Licence: None: All rights reserved

Cite this

@inproceedings{3bce8bcce6094f88b6d92f168e87a4c8,

title = "Implementing CFD modelling to address defect formation in core injection moulding",

abstract = "Ceramic cores are used in casting processes to create complex internal shapes within the final component. The work presented here uses Computational Fluid Dynamics (CFD) analysis to predict the filling and solidification behaviour of ceramic core material during the Ceramic Injection Moulding (CIM) process in the large, complex geometries now typical of modern cores. The aim of the study is to develop a predictive capability to identify key defects in the core that might otherwise only be observed after a number of expensive manufacturing processes. Manufacturing trials using short shots have been carried out in order to validate the transient flow patterns of the paste; this has highlighted the occurrence of jetting, weld lines and flow defects that are highly dependent on the injection parameters and runner designs employed. Analysis of the modelled solidification, shear rates, stagnation points and phase migration has driven die and process optimisation in a production environment.",

keywords = "Ceramic, CFD, CIM, Defect, Injection moulding, Process, Simulation, StarCCM+",

author = "Stefano Cademartori and Nicholas Humphreys and Gebelin, {Jean Christophe} and Jeffery Brooks",

year = "2018",

month = jan,

day = "13",

doi = "10.1007/978-3-319-72059-3_20",

language = "English",

isbn = "9783319720586",

series = "Minerals, Metals and Materials Series",

publisher = "Springer",

pages = "213--222",

booktitle = "CFD Modeling and Simulation in Materials Processing 2018",

note = "International Symposium on CFD Modeling and Simulation in Materials Processing, 2018 ; Conference date: 11-03-2018 Through 15-03-2018",

}

Cademartori, S, Humphreys, N, Gebelin, JC & Brooks, J 2018, Implementing CFD modelling to address defect formation in core injection moulding. in CFD Modeling and Simulation in Materials Processing 2018. Minerals, Metals and Materials Series, vol. Part F3, Springer, pp. 213-222, International Symposium on CFD Modeling and Simulation in Materials Processing, 2018, Phoenix, United States, 11/03/18. https://doi.org/10.1007/978-3-319-72059-3_20

Implementing CFD modelling to address defect formation in core injection moulding. / Cademartori, Stefano; Humphreys, Nicholas; Gebelin, Jean Christophe et al.
CFD Modeling and Simulation in Materials Processing 2018. Springer, 2018. p. 213-222 (Minerals, Metals and Materials Series; Vol. Part F3).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

TY - GEN

T1 - Implementing CFD modelling to address defect formation in core injection moulding

AU - Cademartori, Stefano

AU - Humphreys, Nicholas

AU - Gebelin, Jean Christophe

AU - Brooks, Jeffery

PY - 2018/1/13

Y1 - 2018/1/13

N2 - Ceramic cores are used in casting processes to create complex internal shapes within the final component. The work presented here uses Computational Fluid Dynamics (CFD) analysis to predict the filling and solidification behaviour of ceramic core material during the Ceramic Injection Moulding (CIM) process in the large, complex geometries now typical of modern cores. The aim of the study is to develop a predictive capability to identify key defects in the core that might otherwise only be observed after a number of expensive manufacturing processes. Manufacturing trials using short shots have been carried out in order to validate the transient flow patterns of the paste; this has highlighted the occurrence of jetting, weld lines and flow defects that are highly dependent on the injection parameters and runner designs employed. Analysis of the modelled solidification, shear rates, stagnation points and phase migration has driven die and process optimisation in a production environment.

AB - Ceramic cores are used in casting processes to create complex internal shapes within the final component. The work presented here uses Computational Fluid Dynamics (CFD) analysis to predict the filling and solidification behaviour of ceramic core material during the Ceramic Injection Moulding (CIM) process in the large, complex geometries now typical of modern cores. The aim of the study is to develop a predictive capability to identify key defects in the core that might otherwise only be observed after a number of expensive manufacturing processes. Manufacturing trials using short shots have been carried out in order to validate the transient flow patterns of the paste; this has highlighted the occurrence of jetting, weld lines and flow defects that are highly dependent on the injection parameters and runner designs employed. Analysis of the modelled solidification, shear rates, stagnation points and phase migration has driven die and process optimisation in a production environment.

KW - Ceramic

KW - CFD

KW - CIM

KW - Defect

KW - Injection moulding

KW - Process

KW - Simulation

KW - StarCCM+

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U2 - 10.1007/978-3-319-72059-3_20

DO - 10.1007/978-3-319-72059-3_20

M3 - Conference contribution

AN - SCOPUS:85042304697

SN - 9783319720586

T3 - Minerals, Metals and Materials Series

SP - 213

EP - 222

BT - CFD Modeling and Simulation in Materials Processing 2018

PB - Springer

T2 - International Symposium on CFD Modeling and Simulation in Materials Processing, 2018

Y2 - 11 March 2018 through 15 March 2018

ER -

Implementing CFD modelling to address defect formation in core injection moulding

Abstract

Publication series

Conference

Keywords

ASJC Scopus subject areas

Access to Document

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Cite this