Implementing CFD modelling to address defect formation in core injection moulding

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

Research output: Chapter in Book/Report/Conference proceedingConference 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 languageEnglish
Title of host publicationCFD Modeling and Simulation in Materials Processing 2018
PublisherSpringer
Pages213-222
Number of pages10
ISBN (Electronic)9783319720593
ISBN (Print)9783319720586
DOIs
Publication statusPublished - 13 Jan 2018
EventInternational Symposium on CFD Modeling and Simulation in Materials Processing, 2018 - Phoenix, United States
Duration: 11 Mar 201815 Mar 2018

Publication series

NameMinerals, Metals and Materials Series
VolumePart F3
ISSN (Print)2367-1181
ISSN (Electronic)2367-1696

Conference

ConferenceInternational Symposium on CFD Modeling and Simulation in Materials Processing, 2018
Country/TerritoryUnited States
CityPhoenix
Period11/03/1815/03/18

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

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