Modelling of air pressure effects in casting moulds

Attar, Elham; Homayonifar, P; Babaei, Reza; Asgari, Kaveh; Davami, P.

doi:10.1088/0965-0393/13/6/009

Cited by 11 publications

(6 citation statements)

References 9 publications

(8 reference statements)

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“…Modeling of the mould filling is a very complex process, since many physical phenomena, such as free surface flow, turbulence, surface tension and combination of fluid flow with heat transfer, should be considered. In order to take all these parameters into account, the computing technique tends to be complicated [2].…”

Section: Introductionmentioning

confidence: 99%

“…The formation of various castings defects could be directly related to the fluid flow phenomena involved in the stage of mould filling. For instance, vigorous steam could cause mould erosion; highly turbulent flows could result in air and inclusions entrapments; and relatively slower filling might generate cold shut [2]. Furthermore, porosity, a common defect in casting also could result from improper design of gating system [3].…”

Section: Introductionmentioning

confidence: 99%

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Determination of the critical drop height and critical flow velocity of aluminum alloy (AL-91% Mg-8% Fe-0.4% Zn-0.2%) in gravity sand casting

INEGBEDİON

ORJI

2023

Turkish Journal of Engineering

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Critical drop height Critical velocity Gravity sand casting Finite element method SprueCasting is a manufacturing process in which molten metal is poured through the gating system to fill the mould cavity where it solidifies. Variations in casting parameters by different researchers have led to significant variations in casting guidelines, which have forced Foundry Engineers to carry out a number of trial-and-error runs to create guidelines based on their own experience. These variations in guidelines have led to defects occurring in casting during the mould filling process. This work aimed at determining the critical drop height and critical flow velocity of a certain molten aluminum alloy as it flow down the mould sprue in gravity sand casting. The continuity equation was used to describe the velocity distribution of the aluminum alloy as it flows down the sprue. The mathematical tool used in this research is the finite element method. It involves the discretization of the domain of interest into smaller finite elements. The weak form of the governing equation was obtained and integrated over the domain of interest. The results obtained, established the critical flow velocity of aluminum alloy, down the sprue, as 2.565 × 10 3 mm/s and the critical drop height as 377mm. Results obtained were compared with literature and were also used to produce various casts, it was observed that casts produced, using sprue height below the critical drop height obtained prevented casting defects, while at sprue height above the critical drop height, the danger of casting defects could not be avoided.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Determination of the critical drop height and critical flow velocity of aluminum alloy (AL-91% Mg-8% Fe-0.4% Zn-0.2%) in gravity sand casting

INEGBEDİON

ORJI

2023

Turkish Journal of Engineering

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“…The air as well as other gases, formed due to the thermal degradation of molding materials [1,2], are compressed by the flowing stream and 'pushed out' from the mold via pores in its structure (sand molds) and special venting elements, open feeders etc. Simultaneously, not proper or not efficient enough venting system can cause that gases will constitute a barrier, not allowing the casting alloy to fill completely the mold cavity [3]. In case when the liquid metal motion is accompanied with turbulences, gas bubbles can be also enclosed within the stream which, in consequence, leads to casting defects difficult to be removed [4,5].…”

Section: Introductionmentioning

confidence: 99%

Application of the lattice Boltzmann method for simulation of the mold filling process in the casting industry

et al. 2017

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The aim of this work is the development of the lattice Boltzmann model for simulation of the mold filling process. The authors present a simplified approach to the modeling of liquid metal-gas flows with particular emphasis on the interactions between these phases. The boundary condition for momentum transfer of the moving free surface to the gaseous phase is shown. Simultaneously, the method for modeling influence of gas back pressure on a position and shape of the interfacial boundary is explained in details. The problem of the lattice Boltzmann method (LBM) stability is also analyzed. Since large differences in viscosity of both fluids are a source of the model instability, the so-called fractional step (FS) method allowing to improve the computation stability is applied. The presented solution is verified on the bases of the available reference data and the results of experiments. It is shown that the model describes properly such effects as: gas bubbles formation and air back pressure, accompanying liquid-gas flows in the casting mold. At the same time the proposed approach is easy to be implemented and characterized by a lower demand of operating memory as compared to typical LBM models of two-phase flows.

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“…The function of sprue and runner is to allow the molten metal to completely fill the cavity of casting component. However, uniform flow of the molten metal is required to avoid entrapment of air, metal oxidation and mould erosion [9,10]. This research investigate the effects of designed gating systems components such as varied sprue diameters of 10 mm and 12 mm with increased in-gate number of 1 to 3 on the tensile properties DOI …”

Section: Introductionmentioning

confidence: 99%

Effects of Gating System Design on Tensile Properties of Cast Aluminium 6063 Alloy

Oyetunji¹,

Ayodele²

2015

Acta Metall Slovaca

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The effects of gating system design on the tensile strength properties of cast Al-Mg-Si alloy component were studied, with gating sprue diameters of 10 mm and 12 mm respectively for pressurized and non-pressurized systems. A match plate pattern was made for channels and mould cavity preparation, while the pouring temperature is at 680 0 C maintained as the optimum temperature. The variation with respect to increasing ingate of 1 to 3 was observed, the resulting castings from the gating system were compared for tensile strength using instron tensile test machine. The non-pressurized system with reduced turbulence and increasing cross sectional area towards the mould cavity, had finally increased the tensile strength. The result shows that 2-ingate pressurized gating system with 10 mm sprue diameter designed type has improved tensile strength. While the non-pressurized system with reduced turbulence and increasing cross sectional area towards the mould cavity, had finally increase the tensile strength.

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Modelling of air pressure effects in casting moulds

Cited by 11 publications

References 9 publications

Determination of the critical drop height and critical flow velocity of aluminum alloy (AL-91% Mg-8% Fe-0.4% Zn-0.2%) in gravity sand casting

Determination of the critical drop height and critical flow velocity of aluminum alloy (AL-91% Mg-8% Fe-0.4% Zn-0.2%) in gravity sand casting

Application of the lattice Boltzmann method for simulation of the mold filling process in the casting industry

Effects of Gating System Design on Tensile Properties of Cast Aluminium 6063 Alloy

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