Study on the Consumption Mechanism and Lubrication of Mold Powder Based on Non-Sinusoidal Oscillation Mode

Abstract

A two-dimensional mold model coupled multiphase flow, heat transfer, solidification and mold oscillation was established based on the casting parameters of the mold of plant. The accuracy of the model was verified by comparing the measured by plant and calculated mold powder consumption under the same casting conditions. The mechanism of mold powder consumption and lubrication was analyzed based on the non-sinusoidal oscillation mode, and the effect of non-sinusoidal oscillation parameters on mold powder consumption was discussed. Mold powder consumption was determined by the downward flow velocity of liquid mold powder and the thickness of liquid mold powder film, the liquid mold powder consumption decreased with the decrease of those. When the mold moved downward, the mold powder thickness and downward flow velocity decreased, the minimum mold powder consumption reached at the middle of the negative strip time, and the variation was to opposite when the mold moved upward, the maximum mold powder consumption appeared during the positive strip time. With the decrease of casting speed and modification ratio, and increase of oscillation frequency and oscillation amplitude, the mold powder consumption had the tendency to increase. The nonlinear regression equation was fitted by the Levenberg–Marquardt method combined with the universal global optimization method to evaluate mold powder consumption.