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<p>Wall-thickness uniformity is a key quality index for centrifugally cast ductile iron pipes, yet it is strongly affected by gate geometry and thermal processing parameters. In this study, a three-dimensional multiphysics-coupled model was developed using commercially available simulation software to investigate horizontal centrifugal casting of ductile iron pipes, with particular emphasis on the roles of gate geometry, casting temperature, and mold preheating temperature. The model incorporated fluid flow, heat transfer, solidification, and stress evolution, and was validated through comparison with plant-measured surface temperature and wall-thickness data. The results show that, compared with the circular gate, the horseshoe-shaped gate promotes more uniform melt spreading, alleviates local accumulation and backfilling, and leads to a smaller simulated wall-thickness range. In addition, both casting temperature and mold preheating temperature exhibit suitable process windows with respect to simulated wall-thickness uniformity. A low casting temperature causes premature chilling and insufficient filling stability, whereas an excessively high casting temperature increases free-surface instability and shrinkage mismatch. Similarly, insufficient mold preheating intensifies mold chilling, while excessive preheating delays shell formation and aggravates local stress concentration. Among the investigated cases, the best simulated wall-thickness uniformity was obtained at a casting temperature of 1350&#xa0;°C and a mold preheating temperature of 200&#xa0;°C, with a simulated wall-thickness range of 1.32&#xa0;mm. This value falls within the field-measured wall-thickness range obtained under the selected industrial process condition, providing preliminary engineering validation of the numerical model and the selected parameter combination. The present study provides useful guidance for gate design, parameter optimization, and quality control in horizontal centrifugal casting of ductile iron pipes.</p>

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Effects of Gate Geometry and Process Parameters on Wall-Thickness Uniformity in Horizontal Centrifugal Casting of Ductile Iron Pipes

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Zhixin Li,
  • Min Wang,
  • Lidong Xing,
  • Yanping Bao,
  • Xingang Ai

摘要

Wall-thickness uniformity is a key quality index for centrifugally cast ductile iron pipes, yet it is strongly affected by gate geometry and thermal processing parameters. In this study, a three-dimensional multiphysics-coupled model was developed using commercially available simulation software to investigate horizontal centrifugal casting of ductile iron pipes, with particular emphasis on the roles of gate geometry, casting temperature, and mold preheating temperature. The model incorporated fluid flow, heat transfer, solidification, and stress evolution, and was validated through comparison with plant-measured surface temperature and wall-thickness data. The results show that, compared with the circular gate, the horseshoe-shaped gate promotes more uniform melt spreading, alleviates local accumulation and backfilling, and leads to a smaller simulated wall-thickness range. In addition, both casting temperature and mold preheating temperature exhibit suitable process windows with respect to simulated wall-thickness uniformity. A low casting temperature causes premature chilling and insufficient filling stability, whereas an excessively high casting temperature increases free-surface instability and shrinkage mismatch. Similarly, insufficient mold preheating intensifies mold chilling, while excessive preheating delays shell formation and aggravates local stress concentration. Among the investigated cases, the best simulated wall-thickness uniformity was obtained at a casting temperature of 1350 °C and a mold preheating temperature of 200 °C, with a simulated wall-thickness range of 1.32 mm. This value falls within the field-measured wall-thickness range obtained under the selected industrial process condition, providing preliminary engineering validation of the numerical model and the selected parameter combination. The present study provides useful guidance for gate design, parameter optimization, and quality control in horizontal centrifugal casting of ductile iron pipes.