Modelling of foam degradation in lost foam casting process

In this investigation a new model was developed to calculate gas pressure at the melt/foam interface (Gap) resulting from foam degradation during mould filling in the lost foam casting (LFC) process. Different aspects of the process, such as foam degradation, gas elimination, transient mass, heat transfer, and permeability of the refractory coating were incorporated into this model. A computational fluid dynamic (CFD) code was developed based on the numerical technique of the SOLution Algorithm-Volume of Fluid (SOLA-VOF) utilizing model, for the simulation and prediction of the fluid flow in the LFC process. In order to verify the computational results of the simulation, a thin plate of grey iron was poured into a transparent foam mould. The mould filling process was recorded using a 16 mm high-speed camera. Images were analysed frame by frame, in order to measuring foam depolymerization rate and the gap volume during mould filling. Comparison between the experimental method and the simulation results, for the LFC filling sequence, has shown a good agreement.     

Effect of Process Parameters on Porosity in Aluminum Lost Foam Process

1.IntroductionLost foam casting process is still a new technology,and is gaining confidence among manufacturers[1].It isexpected to dramatically improve the competitiveness ofthe foundry industry.Many advantages like eliminatingmachining steps,making complex casting without coresand reducing environmental loads can be offered by thisprocess,because molding binder is not added into themold of the lost foam process.Aluminum alloy castings are widely used in the auto-mobile and aerospace industri…     

铝(镁)合金消失模铸造近净成形技术研究进展

阐述了铝(镁)合金消失模铸造技术的研究现状,着重介绍了铝(镁)合金消失模铸造在金属液充型、振动凝固、压力凝固以及消失模壳型铸造等技术方面的最新研究进展。研究表明,铝(镁)合金在消失模铸造过程中,需重点解决针孔、缩松等缺陷,提高液态合金的充型能力和铸件的力学性能;通过采用振动凝固和压力凝固的手段,可以提高金属液充型能力、细化组织、提高组织致密性,明显提高铸件力学性能。真空低压消失模壳型铸造技术,可以解决普通消失模铸造易于出现的孔洞和夹杂等缺陷以及浇不足和浇注温度高等问题,是一种生产复杂薄壁高质量铝、镁合金精密铸件的新方法。     

Numerical modeling and experimental verification of mold filling and evolved gas pressure in lost foam casting process

A simple mathematical model is developed to describe a lost foam casting process. Different aspects of the process, such as liquid metal flow, transient heat transfer, foam degradation and gas elimination were incorporated into this numerical model. Fluid velocity, temperature distribution within molten metal and pressure building-up in the mold cavity are predicted as a function of filling time and filling height. The model was verified by comparison of the predicted velocity profiles, temperature fields and back-pressures with the experimental data conducted in this work. Both coated and uncoated foam patterns were used in experimental part of this study. A good agreement between the predictions and the experimental data was found.     

Influence of lustrous carbon defects on the fatigue life of ductile iron castings using lost foam process

Ductile cast irons are technologically important materials and are used extensively in automotive industry. Defects produced during casting process often play a dominant role in limiting mechanical properties and fatigue life under cyclic loading in cast alloy components. In order to investigate the effects of process induced defects on the fatigue behavior, in this paper two batches of ductile iron specimens cast using green sand and lost foam molding processes were studied. The ductile irons produced by lost foam molding generally were characterized to have lustrous carbon defects which left from the foam material. To evaluate the effect of lustrous carbon defects on fatigue performance of lost foam molded specimens, experimental fatigue tests were conducted on the both batches of ductile cast iron specimens to obtain S–N data. These data were used to compare fatigue performance of two batches of specimens. The lost foam molded specimens obviously exhibit lower fatigue life i.e. lower S–N curve than green sand molded specimens. Also, the fatigue life of lost foam molded specimens were predicted using AFGROW software, which works based on linear elastic fracture mechanics (LEFM), by assuming lustrous carbon defects as cracks in which they grow until final fracture under cyclic load. The predicted fatigue lives were compared with the experimental ones.     

Study on Numerical Simulation of Mold Filling and HeatTransfer in Die Casting Process

1. IntroductionDie casting is a very complicated process which involves the high speed flow of molten metal filling into3-dimensional complex geometry. The molten metalflow pattern and the temperature distribution of thedie casting and the dies, have a critical influence onthe quality of the cast products, the production rateand the die life.The application of CAE (computer aided engineering) analysis in die design gradually becomes possibleand popular. The main idea is to analyze or predict…     

Study on Numerical Simulation of Mold Filling and Solidification Processes under Pressure Conditions

The mold filling and solidification simulation for the high pressure die casting (HPDC) and low pressure die casting (LPDC) processes were studied.A mathematical model considering the turbulent flow and heat transfer phenomenon during the HPDC process has been established and paralled computation technique was used for the mold filling simulation of the process.The laminar flow characteristics of the LPDC process were studied and a simplified model for the mold filling process of wheel castings has been developed.For the solidification simulation under pressure conditions,the cyclic characteristics and the complicated boundary conditions were considered and techniques to improve the computational efficiency are discussed.A new criterion for predicting shrinkage porosity of Al alloy under low pressure condition has been developed in the solidification simulation process.     

基于ProCAST的制动铸件精确成形数值模拟与工艺提升

目的 针对排气制动阀铸造工艺控制不当会产生缺陷这一问题,结合模拟分析,提出合理的铸造工艺方案,以减少铸件缺陷。方法 基于ProCAST软件对蝶阀阀体铸造工艺进行模拟,研究阀体铸件在充型、凝固过程中的速度场、温度场、固相率分布和缺陷分布,并根据模拟结果对工艺进行优化。结果 添加侧冒口和冷铁后,阀体的缩松缩孔缺陷得到了有效控制,缺陷体积减少了95%以上,获得了完整铸件。结论 通过铸造模拟有效指导了排气制动用蝶阀的生产实践,优化了生产工艺,节约了生产成本。     

Pressure-driven mold filling model of aluminum alloy melt/semi-solid slurry based on rheological behavior

The pressure-driven mold filling ability of aluminum alloy melt/semi-solid slurry is of great significance in pressure casting processes, and the rheological behavior of the alloy has a crucial effect on the mold filling ability according to fluid dynamics. In this work, a pressure-driven mold filling model is first proposed based on the rheological behavior of the alloys. A356 alloy is employed as an example to clarify the rheological behavior of aluminum alloys, which obeys the power law model and is affected by temperature. The rheological behavior of the alloy in semi-solid state is modelled with the coupling of shear rate and temperature. The stop of mold filling attributes to the pressure loss which is caused by the viscosity during the flow of the melt/semi-solid slurry. Pressure loss caused by viscous flow and heat transfer between the alloy and the mold are calculated and coupled during the mold filling of the melt/semi-solid slurry. A pressure-driven mold filling model of aluminum alloy melt/semi-solid slurry is established based on steady-state rheological behavior. The model successfully predicts the filling length of melt/semi-solid slurry in pressure casting processes. Compared with the experimental results,the model can provide a quantitative approach to characterize the pressure-driven mold filling ability of aluminum alloy melt. The model is capable of describing the stop filling behavior of other aluminum alloys in pressure casting processes with corresponding rheological parameters and heat transfer coefficient.     

Parameter identification and computational simulation of polyurethane foaming process by finite pointset method

Numerical simulation of the polyurethane foaming process is a valuable method to analyze the molding process at an early stage of product development to shorten time-to-market cycles and cut costs by using fewer prototypes. However, this process involves highly coupled thermo-chemo-rheological modeling and needs adequate model parameters’ identification. A theoretical model including chemical reactions and thermo-rheological coupling of conservation equations was developed. Based on the theoretical model, three-dimensional numerical simulation for mold filling of the polyurethane foam was carried out by using Finite Pointset Method (FPM) to predict flow field, flow front advancement, temperature and density distributions during mold filling. A FOAMAT system was used to monitor foam height rise and reaction temperature on a cylindrical test tube and foam viscosity was measured by using a dynamic rotational rheometer with parallel-plate system. The parameters of the model were identified by an inverse analysis method which consists in determining the parameters by comparing the computed quantities to those measured experimentally. The overall modeling was validated by using short shot foams obtained with a panel mold cavity. Mold filling of an automotive underlay carpet cavity was investigated numerically. Flow front results were successfully compared to short shot foams obtained with the industrial mold cavity.     

Mold Filling Behavior of Melts with Different Viscosity under Centrifugal Force Field

Recently proposed mathematical model for mold filling processes under centrifugal field conditions and the computer codes were first tested through the sample simulation of gravity mold filling process for a benchmark plate-casting,which were compared with quoted experimental observations.The model and the developed computer program were then applied to the numerical simulation of centrifugal field mold filling processes for a thin-section casting with a titanium alloy melt of assumed viscosity of 1.2 and 12.0mm^2/s,respectively.The computation result comparison shows that the flow behaviors of the filling melts are basically similar to each other although the less viscous melt tends to fill into the thin section casting cavity faster.     

Discrete element modelling and simulation of sand mould manufacture for the lost foam process

This paper presents a numerical model of mould manufacture for the lost foam casting process. The process of mould filling with sand and sand compaction by vibration are modelled using spherical (in 3D) or cylindrical (in 2D) discrete elements. The motion of discrete elements is described by means of equations of rigid body dynamics. Rigid particles interact among one another with contact forces, both in normal and tangential directions. Numerical simulation predicts defects of the mould due to insufficient sand compaction around the pattern. Combining the discrete element model of sand with the finite element model of the pattern allows us to detect possible distortion of the pattern during mould filling and compaction. Results of numerical simulation are validated by comparison with experimental data. Copyright © 2004 John Wiley & Sons, Ltd.     

熔模精铸型壳预热转移过程温度场及换热规律研究

目的 为了获得不同工艺条件对高温合金熔模铸造型壳在预热及转移过程中温度分布的影响规律.方法 根据实际工况设计了测温实验方案,采用热电偶测温的方法研究型壳在无保温措施、外加保温棉、填砂以及保温棉复合填砂4种工艺条件下对型壳在预热及转移过程中温度分布的影响.获得了型壳升温、保温和转移过程中的温度场变化曲线,并根据实际测温曲...     

球铁后桥壳的铸造工艺设计及数值模拟

首先对后桥壳进行初步的铸造工艺方案设计,然后运用铸造数值模拟软件华铸CAE对其充型和凝固过程进行模拟,预测可能产生的铸造缺陷及部位,分析缺陷产生的主要原因,从而改进工艺.经多次CAE模拟优化获得最优工艺,可减少铸造缺陷,保证铸件质量.     

EPS molecular weight and foam density effects in the lost foam process

The effects of pattern molecular weight and density on casting formation in the lost foam process have been studied. The tensile properties of injection molded ASTM D638 tensile rods have been measured for various densities and molecular weights. Thermogravimetry, differential scanning calorimetry and other techniques have been used to study the thermal degradation characteristics of the pattern. A thermometric technique has been used to study the mold filling behavior with aluminum alloy A356. The results indicate that the tensile properties in the foam generally improve with increasing molecular weight and density. The structural characteristics of the foam may have a greater influence on mechanical properties than molecular weight. The rate of volatilization of the polymer increases as the weight average molecular weight, M _w, is lowered from 304,000 g/mol to 152,000 g/mol. The mold fill time increases with pattern density and M _w. The data suggest that pattern density and molecular weight may have a significant effect on the quality of the casting.     

基于UG 与CAE 的压力机底座铸造工艺设计与数值模拟

目的通过对压力机底座的充型凝固过程进行数值模拟,预测其浇铸质量同时基于模拟结果提出相应的工艺改进措施。方法使用UG与CAE软件对压力机底座铸造工艺进行三维建模和数值模拟分析。通过研究零件的结构特点,确定选取砂型手工铸造方法,并使用三箱造型,选取合适的分型面与浇铸位置。采用UG软件做出锻压机底座的三维模型和浇注系统设计,然后利用Anycasting软件进行充型模拟。对充型与凝固过程进行了整体的缺陷分析。结果利用Anycasting模拟浇铸过程发现,在整个充型过程中,充型平稳,无卷气、夹渣、缩孔、缩松等缺陷的出现。结论通过模拟结果确定了浇注系统和补缩系统设计合理,相应工艺设计合理,可以铸造出符合要求的压力机底座。     

球墨铸铁球化不良和衰退的仿真研究

在球铁件缺陷诊断的神经网络模型基础上 ,借助于MATLAB环境中的NEURALNETWORKTOOLBOX工具箱 ,对球铁件球化不良与球化衰退和一些主要影响因素间关系进行了仿真研究 ,并对得到的仿真趋势图进行了详细的分析。仿真表明 ,严格控制各化学成分及浇注温度可有效地消除球化不良和衰退 ,对提高球铁件质量及控制球铁生产工艺参数具有积极作用。该方法大大方便了球铁缺陷的分析 ,可有效地应用于实际生产中。     

Physical Simulation of Mold-Filling Processing of Thin-Walled Castings under Traveling Magnetic Field

Mold-filling process of thin-walled castings under the condition of traveling magnetic field has been studied by physical simulation method using gallium melt and fast speed photography. Flow morphology and its formation mechanism were obtained and discussed for thin-walled casting. The influences of magnetic field density on the filling ability, filling velocity and mold filling time have been studied. The differences in filling capability between gravity casting and casting under the traveling magnetic field have been compared. The results indicate that the mold filling ability of the gallium melt increases greatly under the condition of traveling magnetic field; the filling time is shortened from 18 s under gravity field to 3 s under the traveling magnetic field and average flow rate of the melt increases from 1.6 to 8.68 cm3/s; the change law of the cross-section morphology of the gallium melt during the mold filling is that at first, the cross-section area does not change, then it decreases gradual     

Numerical simulation of the casting process of titanium removable partial denture frameworks

The objective of this work was to study the filling incompleteness and porosity defects in titanium removal partial denture frameworks by means of numerical simulation. Two frameworks, one for lower jaw and one for upper jaw, were chosen according to dentists recommendation to be simulated. Geometry of the frameworks were laser-digitized and converted into a simulation software (MAGMASOFT). Both mold filling and solidification of the castings with different sprue designs (e.g. tree, ball, and runner-bar) were numerically calculated. The shrinkage porosity was quantitatively predicted by a feeding criterion, the potential filling defect and gas pore sensitivity were estimated based on the filling and solidification results. A satisfactory sprue design with process parameters was finally recommended for real casting trials (four replica for each frameworks). All the frameworks were successfully cast. Through X-ray radiographic inspections it was found that all the castings were acceptably sound except for only one case in which gas bubbles were detected in the grasp region of the frame. It is concluded that numerical simulation aids to achieve understanding of the casting process and defect formation in titanium frameworks, hence to minimize the risk of producing defect casting by improving the sprue design and process parameters.     

Numerical study of porosity in titanium dental castings

A commercial software package, MAGMASOFT (MAGMA Giessereitechnologie GmbH, Aachen, Germany), was used to study shrinkage and gas porosity in titanium dental castings. A geometrical model for two simplified tooth crowns connected by a connector bar was created. Both mold filling and solidification of this casting model were numerically simulated. Shrinkage porosity was quantitatively predicted by means of a built-in feeding criterion. The risk of gas pore formation was investigated using the numerical filling and solidification results. The results of the numerical simulations were compared with experiments, which were carried out on a centrifugal casting machine with an investment block mold. The block mold was made of SiO₂ based slurry with a 1 mm thick Zr₂ face coat to reduce metal–mold reactions. Both melting and casting were carried out under protective argon (40 kPa). The finished castings were sectioned and the shrinkage porosity determined. The experimentally determined shrinkage porosity coincided with the predicted numerical simulation results. No apparent gas porosity was found in these model castings. Several running and gating systems for the above model casting were numerically simulated. An optimized running and gating system design was then experimentally cast, which resulted in porosity-free castings. © 1999 Kluwer Academic Publishers