The improvement of aluminium casting process control by application of the new CRIMSON process

All The traditional foundry usually not only uses batch melting where the aluminium alloys are melted and held in a furnace for long time, but also uses the gravity filling method in both Sand Casting Process (SCP) and Investment Casting Process (ICP). In the gravity filling operation, the turbulent behaviour of the liquid metal causes substantial entrainment of the surface oxide films which are subsequently trapped into the liquid and generate micro cracks and casting defects. In this paper a new CRIMSON process is introduced which features instead of gravity filling method, using the single shot up-casting method to realize the rapid melting and rapid filling mould operations which reduce the contact time between the melt and environment thus reducing the possibility of defect generation. Another advantage of the new process is the drastic reduction of energy consumption due to shortened melting and filling time. Two types of casting samples from SCP and ICP were compared with the new process. The commercial software was used to simulate the filling and solidification processes of the casting samples. The results show that the new process has a more improved behaviour during filling a mould and solidification than the two conventional casting processes

Electroconvective instability in a fluid layer

Electroconvective instabilities in fluid laye

Assessment of casting filling by modeling surface entrainment events using CFD

The reliability of cast components is dependent on the quality of the casting process. During this highly transient filling phase the prevention of free surface turbulence and consequential oxide entrainment is critical to ensure the mechanical integrity of the component. Past research has highlighted a number of events that lead to entrainment of surface oxides. Using FLOW-3D, flow structures that result in surface entrainment events have been simulated and an algorithm developed that allows entrainment and defect motion to be tracked. This enables prediction of the quantity and motion of oxide film generated from each event. The algorithm was tested experimentally and compared to experimental data from previously published work. A quantitative criterion is proposed to assess the damage of each type of event. Complete running systems have also been studied to understand how they could be assessed for quality of filling based on the flows within them

Movements and social behaviour of the opossum, Trichosurus vulpecula KERR, in a mixed scrub, bush and pasture habitat

The movements of Australian brush-tailed opossums, Trichosurus vulpecula, were studied in a mixed bush, scrub, and pasture habitat on Banks Peninsula by live-trapping and spotlighting over a period of six months from February to July 1971. Thirty-four opossums were marked. Estimates of the size of ranges in the pasture (0.8 ha males; 0.3 ha females) were smaller than those found elsewhere, probably because of the restricted habitat. Range sizes of animals resident in the bush were considerably altered by their movements" to seasonal food sources in the pasture. Male opossums did not hold territories as described in some studies. In this mixed habitat opossums may move between scrub, bush and pasture to obtain food and shelter

Design and development of a hybrid flexible manufacturing system : a thesis presented in fulfilment of the requirements for the degree of Master of Technology at Massey University

Volumes 1 and 2 merged.The ability of a manufacturing environment to be able to modify itself and to incorporate a wide variety of heterogeneous multi-vendor devices is becoming a matter of increasing importance in the modern manufacturing enterprise. Many companies in the past have been forced to procure devices which are compatible with existing systems but are not as suitable as other less compatible devices. The inability to be able to integrate new devices into an existing company has made such enterprises dependent on one vendor and has decreased their ability to be able to respond to changes in the market. It is said that typically 60% of orders received in a company are new orders. Therefore the ability of a company to be able to reconfigure itself and respond to such demands and reintegrate itself with new equipment requirements is of paramount importance. In the past much effort has been made towards the integration of shop floor devices in industry whereby such devices can communicate with each other so that certain tasks are able to be achieved in a single environment. Up until recently however much of this was carried out in a very much improvised fashion with no real structure existing within the factory. This meant that once the factory was set up it became a hard-wired entity and extensibility and modiflability were difficult indeed. When formalised Computer Integrated Manufacturing (CIM) system architectures were developed it was found that although they solved many existing shortcomings there were inherent problems associated with these as well. What became apparent was that a fresh approach was required that took the advantages of existing architectures and combined them into an new architecture that not only capitalised on these advantages but also nullified the weaknesses of the existing systems. This thesis outlines the design of a new FMS architecture and its implementation in a factory environment on a PC based system

The modelling of oxide film entrainment in casting systems using computational modelling

As Campbell stated in 2006, “the use of entrainment models to optimise filling systems designs for castings has huge commercial potential that has so far being neglected by modellers”. In this paper a methodology using computational modelling to define entraining events and track the entrained oxide films is presented. Research has shown that these oxide films present within the casting volume are highly detrimental to casting integrity, thus their entrainment during mould filling is especially undesirable. The method developed for the modelling of oxide entrainment has been validated against previously published data by Green and Campbell (1994) [31]. The validation shows good quantitative correlation with experimental data. However there is scope for further development which has the potential to both improve the accuracy and further validate the technique

Continuous data assimilation with blurred-in-time measurements of the surface quasi-geostrophic equation

An intrinsic property of almost any physical measuring device is that it makes observations which are slightly blurred in time. We consider a nudging-based approach for data assimilation that constructs an approximate solution based on a feedback control mechanism that is designed to account for observations that have been blurred by a moving time average. Analysis of this nudging model in the context of the subcritical surface quasi-geostrophic equation shows, provided the time-averaging window is sufficiently small and the resolution of the observations sufficiently fine, that the approximating solution converges exponentially fast to the observed solution over time. In particular, we demonstrate that observational data with a small blur in time possess no significant obstructions to data assimilation provided that the nudging properly takes the time averaging into account. Two key ingredients in our analysis are additional boundedness properties for the relevant interpolant observation operators and a non-local Gronwall inequality.Comment: 44 page

Helicopter main-rotor noise: Determination of source contributions using scaled model data

Acoustic data from a test of a 40 percent model MBB BO-105 helicopter main rotor are scaled to equivalent full-scale flyover cases. The test was conducted in the anechoic open test section of the German-Dutch Windtunnel (DNW). The measured data are in the form of acoustic pressure time histories and spectra from two out-of-flow microphones underneath and foward of the model. These are scaled to correspond to measurements made at locations 150 m below the flight path of a full-scale rotor. For the scaled data, a detailed analysis is given for the identification in the data of the noise contributions from different rotor noise sources. Key results include a component breakdown of the noise contributions, in terms of noise criteria calculations of a weighted sound pressure level (dBA) and perceived noise level (PNL), as functions of rotor advance ratio and descent angle. It is shown for the scaled rotor that, during descent, impulsive blade-vortex interaction (BVI) noise is the dominant contributor to the noise. In level flight and mild climb, broadband blade-turbulent wake interaction (BWI) noise is dominant due to the absence of BVI activity. At high climb angles, BWI is reduced and self-noise from blade boundary-layer turbulence becomes the most prominent