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JOURNALOFUNIVERSITYOFSCIENCEANDTECHNOLOGYBEIJIREGVOLUME13,NUMBER1,FEBRUARY2006,PAGE60MATERIALSEVALUATIONOFTHEMOLDFILLINGABILITYOFALLOYMELTINSQUEEZECASTINGHAIYINGZHANG’,SHUMINGXING’,QINGHUAZHANG’’,JIANBOANDWENLID1SEMISOLIDFORMINGRESEARCHCENTER,BEIJINGJIAOTONGUNIVERSITY,BEIJING100044,CHINA2SHIJIAZHUANGLOCOMOTIVEDEPOT,SHIJIAZHUANG050000,CHINA3DEPARTMENTOFMATERIALANDENGINEERING,HEBEIUNIVERSITYOFSCIENCEANDTECHNOLOGY,SHIJIAZHUANG050018,CHINARECEIVED20041213ABSTRACTTHEMOLDFILLINGABILITYOFALLOYMELTINSQUEEZECASTINGPROCESSWASEVALUATEDBYMEANSOFTHEMAXIMUMLENGTHOFARCHIMEDESSPIRALLINEATHEORETICALEVALUATINGMODELTOPREDICTTHEMAXIMUMFILLINGLENGTHWASBUILTBASEDONTHEFLOWINGTHEORYOFTHEINCOMPRESSIBLEVISCOUSFLUIDITWASPROVEDBYEXPERIMENTSANDCALCULATIONSTHATTHEMOLDFILLINGPRESSUREANDVELOCITYAREPROMINENTINFLUENCINGFACTORSONTHEMOLDFILLINGABILITYOFALLOYMELTTHEMOLDFILLINGABILITYINCREASESWITHTHEINCREASEOFTHEMOLDFILLINGPRESSUREANDTHEDECREASEOFTHEPROPERMOLDFILLINGVELOCITYMOREOVER,THEPOURINGTEMPERATURERELATIVELYHASLESSEFFECTONTHEMOLDFILLINGABILITYUNDERTHEEXPERIMENTALCONDITIONSTHEMAXIMUMDEVIATIONOFTHEORETICALCALCULATINGVALUESWITHEXPERIMENTALRESULTSISLESSTHAN15THEMODELCANQUANTITATIVELYESTIMATETHEEFFECTOFEVERYFACTORONTHEMOLDFILLINGABILITYKEYWORDSSQUEEZECASTING;PROCESSPARAMETERS;MOLDFILLINGABILITY;THEORETICALCALCULATION;EXPERIMENTALEVALUATION1INTRODUCTIONTHEMOLDFILLINGABILITYOFALLOYMELTCANDIRECTLYAFFECTTHEINNERQUALITYANDSURFACEROUGHNESSOFTHEPRODUCTS,ANDISREGARDEDASABASICPROBLEMINTHEFIELDOFMATERIALFORMINGPROCESS,ESPECIALLYINTHERESEARCHESOFNEWMATERIALSANDPROCESSESINTHETRADITIONALCASTINGTECHNOLOGY,THEEVALUATIONOFTHEMOLDFILLINGABILITYISCARRIEDONBYMEASURINGTHEMAXIMUMFILLINGLENGTHOFASPIRALLINESPECIMEN;HOWEVER,THISEVALUATIONISLIMITEDFORCASTINGMATERIALS,MOULDMATERIALS,POURINGTECHNOLOGIESANDFORMINGMETHODSHENCEINSPECIALCASTINGPROCESSSUCHASSQUEEZECASTING,SEMISOLIDMETALCASTING,LOSTFOAMCASTINGANDSOON,ITISANEWPROBLEMTOEVALUATETHEMOLDFILLINGABILITYOFALLOYMELTSMXINGINVESTIGATEDTHEMOLDFILLINGABILITYOFSEMISOLIDALLOYINTHEMOLDWITHMANYHOLESOFDIFFERENTDIAMETERSUNDERAPRESSURE,ANDPROPOSEDATHEORETICALFORMULAOFTHEFILLINGLENGTH11RECENTLY,JULIOAGUILAR2DESIGNEDAMEANDERSAMPLEOFAZ91ALLOYWITHALENGTHOF2420MMTOEVALUATETHEFILLINGABILITYOFALLOYSINTHEDIECASTINGPROCESSBECAUSETHEREISNOTANAVAILABLEFORMULATOPREDICTFILLINGLENGTH,THISEVALUATIONMETHODISNOTCONVENIENTINENGINEERINGTJZHANG3INVESTIGATEDTHERELATIONSHIPBETWEENMAGNETICFLUXDENSITYANDINPUTVOLTAGEASWELLASDISTANCE,ANDFOUNDTHATTHEMOLDFILLINGLENGTHOFTHEMELTINCREASESRAPIDLYWITHTHEINCREASEOFTHEAVERAGEMAGNETICFLUXDENSITY,ANDCORRESPONDINGAUTHORHAIYINGZHANG,EMAILYINGYINGZH126COMTHATTHEUPPERSTEELMOLDISSUPERIORTOTHEUPPERGYPSUMMOLDMOREOVER,INRESEARCHINGONHIGHPRESSUREDIECASTING,SKULASEGARAM4,ZLIU5,ANDCLEARYPAUL6STUDIEDTHEMOLDFILLINGABILITYOFALLOYSBYSIMULATIONSENPAN7STUDIEDTHEEFFECTSOFPOURINGTEMPERATURE,COATINGTHICKNESSETCONTHEMOLDFILINGABILITYOFLOSTFOAMA356ALLOY,THECALCULATEDFLOWLENGTHBASEDONAMODIFIEDEPCFLOWSOLIDIFICATIONEQUATIONSHOWEDAGOODAGREEMENTWITHTHEEXPERIMENTALRESULTSTHEEVALUATIONMETHODOFMOLDFILLINGABILITYMAINLYINCLUDESTHREETYPES,EXPERIMENTALEVALUATION,THEORETICALCALCULATION,ANDSIMULATIONTHEEXPERIMENTALEVALUATIONMETHODISABASICONEBECAUSEOFITSINTUITIONALEFFECTS,BUTITISLIMITEDFORTHEEXPERIMENTALCONDITIONSANDISDIFFICULTFORPOPULARUSETHESIMULATIONMETHODISNOTCONVENIENTINENGINEERINGTHOUGHITISMOREEXACTTHANTHEEXPERIMENTALMETHODINGIVENCONDITIONSHOWEVER,THETHEORETICALCALCULATIONMETHODCANBEUSEDCONVENIENTLYTOPREDICTTHEFILLINGABILITYOFVARIOUSALLOYSINVARIOUSPROCESSESWITHOUTANYSPECIALEQUIPMENTSQUEEZECASTINGISANEWFORMINGTECHNOLOGYTHATISEXPECTEDTOBEWIDELYUSEDINTHEFUTUREHOWEVER,THEFILLINGABILITYOFALLOYMELTINTHEPROCESSISNOTCLEARSTUDIESEVALUATINGTHEMOLDFILLINGABILITYOFALLOYMELTINSQUEEZECASTINGAREFEWINTHISARTICLE,EXPERIMENTALEVALUATIONANDTHEORETICALCALCULATIONARECOMBINED,ANDAMATHEMATICALMODELFORCALCULATINGMOLDFILLINGABILITYISOBTAINEDHYZHNGETAL,EVALUATIONOFTHEMOLDFILLINGABILITYOFALLOYMELTINSQUEEZECASTING612EXPERIMENTALEVALUATIONOFTHEMOLDFILLINGABILITYINSQUEEZECASTINGBASEDONSPIRALLINESPECIMENINGRAVITYCASTING,ASPECIALSPIRALLINESPECIMENMOLDISDESIGNEDSHOWNINFIGL,WHICHISUSEDFOREXPERIMENTALEVALUATIONOFTHEMOLDFILLINGABILITYOFALLOYMELTINSQUEEZECASTINGTHEMOLDISMADEOFH13STEELITSCONSTRUCTIONMAINLYINCLUDESTHREEPARTS,THEUPPERMOLD,THELOWERMOLD,ANDTHEPUNCHFITTEDONTHEGLIDEPIECEOFTHEFORMINGDEVICE,THEUPPERMOLDHASANARCHIMEDESSPIRALLINECAVITYWITHATOTALLENGTHOF1350MMTHELOWERMOLDISFITTEDONTHEWORKTABLEOFTHEFORMINGDEVICE;ITSMOLDCAVITYISTHECYLINDRICALPRESSINGCHAMBERINTHESIDEWALLOFTHEPRESSINGCHAMBER,THEREISARUNNERTHATCONNECTSWITHTHEARCHIMEDESSPIRALLINECAVITYTHEPUNCHCONNECTSWITHMOLDFILLINGPISTONOFTHEFORMINGDEVICETHEFORMINGDEVICEISTHEDOUBLEACTIONHYDRAULICPRESSESWHICHHASTHEFUNCTIONSSUCHASMOLDLOCKING,MOLDFILLING,EJECTING,ANDMOLDFILLINGVELOCITYTRANSITINGTHEPROCESSPARAMETERSSUCHASMOLDFILLINGPRESSURE,PRESSINGVELOCITYMOLDFILLINGVELOCITYETCCANBESETANDTHEEXPERIMENTALDATACANBESAVEDAUTOMATICALLYBYACOMPUTERCONTROLLINGSYSTEMTHEFORMINGTYPEISINVERTEDEXTRUSIONINWHICHTHEALLOYMELTINTHECYLINDRICALCHAMBERISPR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