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Technical Review and Discussion
A Casting Yield Optimization Case Study: Forging Ram P. Kotas, C. Tutum, J. Hattel, Technical University of Denmark, Lyngby, Denmark O. Šnajdrová, Vitkovice Heavy Machinery A.S., Ostrava, Czech Republic J. Thorborg, Technical University of Denmark, Lyngby, Denmark, MAGMA GmbH, Aachen, Germany
Reviewer: Can any sensitivities be evaluated after all the simulations are run to determine if other factors should be studied, e.g. upper chills required or effect on riser size?
Authors: A classical sensitivity analysis is possible to carry out in the optimization software. It was done to evaluate if both of our objective functions are sensitive to the pre-
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Niyama Criterion”, Metallurgical and Materials Transactions A, vol. 40A, pp. 163-175 (2009).
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25. Jain, N., Carlson, K.D., Beckermann, C., “Round Robin Study to Assess Variations in Casting Simulation Niyama Criterion Predictions,” in Proceedings of the 61st
Technical and Operating Conference, SFSA, Chicago. IL (2007).
26. Carlson, K.D., Ou, S., Hardin, R.A., Beckermann, C., “Development of a Methodology to Predict and Prevent Leaks Caused by Microporosity in Steel Castings,” in Proceedings of the 55th
Operating Conference, SFSA, Chicago IL (2001).
27. Hardin, R.A., Ou, S., Carlson, K.D., Beckermann, C., “Development of New Feeding Distance Rules Using Casting Simulation; Part I: Methodology”, Metallurgical and Materials Transactions B, vol. 33B, pp. 731-740 (2002).
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defined design variables. And they are. However, this analy- sis was not stated in the paper, due to its already large size. If the question is whether the optimization software proposes some more design variables or factors that might be influen- tial , the answer is NO, this was not done and is not possible to do. Every time, a user has to define all the variables, con- straints, objectives and other parameters and the software only works with those.
Reviewer: Were any trials run for the optimized solution to ensure casting soundness and that no other defects were cre- ated due to the recommended changes?
Authors: No casting trials based on the optimized solu- tions and proposals have been performed by the foundry yet. However, there is a promise from them to take our results into considerations, apply the findings and perform the riser volume reduction in the next casting batch.
International Journal of Metalcasting/Fall 10 Technical and
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