Numerical optimization of the taper a vertically cast plate

The temperature field of the studied plate was analyzed with different angles of widening in its cross section (in the range from 0° to 4.4°). From the inclined side, the plate was either insulated or uninsulated. Plastizol was used as an insulator. An uninsulated plate has a calculated optimum angular expansion of 3°. A widening of 2° is the minimum angle at which internal defects (e.g. shrinkage voids) begin to disappear. The insulated plate has an optimum angle of 2°. Using numerical calculations, it is possible to predict that after crystallization without insulation, the plate itself with a widening of 3° will have the same internal quality as a widening of 2° with insulation. The knowledge gained from this study can lead to a reduction in the volume of liquid metal used and also to a reduction in machining costs. These research results have already been successfully applied to the design of the technology for casting nodular cast iron cylinder liners.