Abstract
The optimum gating system for manufacturing turbine housing is designed in this study, and a heater as heat source is provided to the riser, attempting to reduce its size. In the case where the runner is divided into two branches, a symmetrical gating system is adopted so that the two products could be produced in one process. Furthermore, cross-sectional shapes of the sprue, runner, and gate are designed by setting the sprue:runner:gate ratio at 1:0.9:0.6. A casting analysis is then conducted to investigate the effects of shape of the riser, sleeve material, temperature of the heater, and provision of insulation material at the top of the riser. The conditions obtained from the analysis are applied to the experiment. Hot spot defects calculated by casting simulation are reduced when sand sleeve material, straight type riser, open top sleeve, and more than 600°C of heater temperature are used. It is possible to produce a casting with almost no surface defects by adopting a riser with a size of 10–20 mm and a heater of 600°C–700°C. A casting recovery rate of 80% is achieved and, regarding mechanical properties, its tensile strength is 534 MPa, its elongation rate is 9%, and its Brinell hardness is 170 HB.
Highlights
A turbocharger system is a device that improves the charging efficiency of a mixed gas by converting the pressure energy from the exhaust gas of an engine into rotatory power for a turbine, improving engine output and fuel efficiency
The turbine and compressor wheels are connected through an axis; the rotatory force of the turbine wheel acts as a rotatory force for the compressor.[1,2]
Because the theoretical temperature of the liquid phase line of the Gray Casting Ductile (GCD) 600 material was 1169°C after the molten metal was completely filled into the mold cavity, solidification was executed while the molten metal was static
Summary
A turbocharger system is a device that improves the charging efficiency of a mixed gas by converting the pressure energy from the exhaust gas of an engine into rotatory power for a turbine, improving engine output and fuel efficiency. The housing of a turbine has an irregular shape, with a thickness of less than 10 mm This leads to the generation of many defects, adding challenges to the manufacturing process. The high-silicon series spheroidal graphite cast iron is cast and has a low manufacturing cost; it is used in exhaust manifolds and turbine housings, which are operated in a high-temperature environment. It is difficult to use high-silicon series spheroidal graphite cast iron for products with a thickness of less than 10 mm.[4,5,9,10]. An optimal gating system for turbine housing casting was designed, and a heater as heat source was provided to the riser, attempting to reduce its size. Brinell hardness test for the casted product and the tensile test for casted Y-block were performed as part of the analysis of physical properties
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