Experimental study on the filling process of the lost foam casting process of a cast iron plate

2013 ◽  
Vol 47 (1/2/3/4) ◽  
pp. 188 ◽  
Author(s):  
Jinwu Kang ◽  
Xiaokun Hao ◽  
Gang Nie ◽  
Haimin Long ◽  
Tianjiao Wang ◽  
...  
Keyword(s):  
Experimental Study ◽  
Cast Iron ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Filling Process ◽  
Iron Plate ◽  
Lost Foam

Numerical Modeling of EPS Foam Decomposition in the Lost Foam Casting Process

2005 ◽  
Author(s):  
X. J. Liu ◽  
S. H. Bhavnani ◽  
R. A. Overfelt
Keyword(s):  
Heat Transfer ◽  
Process Parameters ◽  
Experimental Studies ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Interfacial Heat Transfer Coefficient ◽  
Filling Process ◽  
Foam Pattern ◽  
Lost Foam

The importance of smooth mold filling in the lost foam casting process has been recognized for a long time. The more uniform the filling process, the better the quality of the casting products that are produced. Successful computer simulations can help reduce the number of trials and cut down the lead time in the design of new casting products by better understanding the complex mechanisms and interplay of different process parameters in the mold filling process. In this study, a computational fluid dynamics (CFD) model has been developed to simulate the fluid flow of molten aluminum and the heat transfer involved at the interfacial gap between the metal and the expanded polystyrene (EPS) foam pattern. The commercial code FLOW-3D was used because it can track the front of the molten metal by a Volume of Fluid (VOF) method and allow complicated parts to be modeled by the Fractional Area/Volume Ratios (FAVOR) method. The code was modified to include the effects of varying interfacial heat transfer coefficient based on gaseous gap pressure which is related to foam degradation and coating permeability. The modification was validated against experimental studies and the comparison showed better agreement than the basic model. Process parameters such as initial metal temperature, foam pattern property, and gating system were investigated. The defect prediction model was also used to study the dependence of defect formation on the process variables.

Filling Pattern of Step Gating System in Lost Foam Casting Process and its Application

2012 ◽  
Vol 602-604 ◽  
pp. 1916-1921 ◽  
Author(s):  
Hong Zhou ◽  
Li Heng Luo
Keyword(s):  
Liquid Metal ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Casting Defect ◽  
Gating System ◽  
Filling Process ◽  
Filling Pattern ◽  
Metal Volume ◽  
The Common ◽  
Lost Foam

To explore application of step gating system in LFC, filling process of two types of step gating system was simulated, their filling patterns were found, and several engineering examples were analyzed basing on these patterns. It was found the metal start filling through all ingates almost simultaneously if the gating system is open, otherwise the sequence of the ingate filling follow increasing sequence of streamline length from the inlet. It was also found the metal volume through each ingate increased gradually bottom-top when the common step gating system is filled by EPS, but when the common step gating system is open or step gating system have an auxiliary sprue, the metal volume decreases gradually. Analysis on several engineering examples shows the simulation confluence of two liquid metal fronts is basically in accordance with the casting defect locations.

scholarly journals The Influence of the Shape of the Reaction Chamber on Spheroidisation of Cast Iron Produced in the Lost Foam Casting Process with Use of the Inmold Method

2012 ◽  
Vol 12 (2) ◽  
pp. 175-178
Author(s):  
P. Just ◽  
T. Pacyniak
Keyword(s):  
Cast Iron ◽  
Casting Process ◽  
Reaction Chamber ◽  
Lost Foam Casting ◽  
Reaction Chambers ◽  
Nodular Graphite ◽  
Lost Foam

The Influence of the Shape of the Reaction Chamber on Spheroidisation of Cast Iron Produced in the Lost Foam Casting Process with Use of the Inmold Method The article presents the results of the research on the influence of the shape of reaction chamber on spheroidisation of cast iron produced with use of the inmold method. The amounts of nodular graphite precipitates in castings produced with the use of different reaction chambers have been compared.

The Lost Foam Casting Simulation of the Gray Cast Iron Linner

2013 ◽  
Vol 834-836 ◽  
pp. 1580-1583
Author(s):  
Shu Heng Yang ◽  
Xiao Ming Du
Keyword(s):  
Cast Iron ◽  
Gray Cast Iron ◽  
Casting Process ◽  
Simulation Method ◽  
Gray Cast ◽  
Lost Foam Casting ◽  
Pouring Temperature ◽  
Technical Parameters ◽  
Lost Foam ◽  
Filling And Solidification

The lost foam casting process of gray cast iron linner was simulated in this paper by using the numerical simulation method to study the properties of the filling and solidification for lost foam casting. And the comparison of the simulated results with the practical casting obtained from foundry was implemented. The results show that the reasonable technical parameters were obtained: pouring temperature of 1400°C, foam density of 13 kg/m3, vacuum of 0.04MPa, coating thickness of 0.5 mm and coating permeability of 9.5×10-9m2/Pa·s.

EXPERIMENTAL STUDY OF LOST FOAM CASTING

2018 ◽  
Vol 13 (4) ◽  
pp. 46
Author(s):  
PRASAD T. SIVA ◽  
M. DEVAIAH ◽  
◽  
Keyword(s):  
Experimental Study ◽  
Lost Foam Casting ◽  
Lost Foam

Synthesis and Characterization of New Refractory Coatings Based on Talc, Cordierite, Zircon and Mullite Fillers for Lost Foam Casting Process

2014 ◽  
Vol 59 (1) ◽  
pp. 89-95 ◽  
Author(s):  
A. Prstić ◽  
Z. Aćimović-Pavlović ◽  
A. Terzić ◽  
L. Pavlović
Keyword(s):  
Microstructural Analysis ◽  
Casting Process ◽  
Lost Foam Casting ◽  
X Ray Diffraction ◽  
X Ray ◽  
Software Application ◽  
Design And Optimization ◽  
Refractory Coatings ◽  
Particle Size And Shape ◽  
Lost Foam

Abstract Refractory coatings based on different refractory fillers (talc, cordierite, zircon and mullite) for application in Lost Foam casting process were investigated. Design and optimization of the coatings composition with controlled, rheological properties included, and consequently synthesis were achieved by application of different coating components, namely different suspension agents and fillers and by alteration of the coating production procedure. Morphologic and microstructural analysis of fillers was carried out by means of scanning electronic microscope. X-ray diffraction analysis by means of X-ray diffractometer was applied in determination and monitoring the phase composition changes of the refractory fillers. An analysis of the particle size and shape was carried out by means of the PC software application package OZARIA 2.5. To assess the effects of application of individual refractory coatings, a detailed investigation of structural and mechanical properties of the moldings obtained was performed. Highlight was placed on revealing and analyzing surface and volume defects present on moldings. Radiographic molding tests were carried out by means of the X-ray device SAIFORT type-S200. Attained results are essential for the synthesis of refractory coatings based on high-temperature fillers and their applications in Lost Foam casting process for manufacturing of moldings with in-advance-set properties.

Numerical Simulation of Molten Metal-Polymeric Foam Interface Velocity During Lost Foam Casting

2001 ◽  
Author(s):  
Sayavur I. Bakhtiyarov ◽  
Ruel A. Overfelt
Keyword(s):  
Molten Metal ◽  
Flow Model ◽  
Interface Velocity ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Foam Material ◽  
Polymeric Foam ◽  
Gaseous Products ◽  
3D Software ◽  
Lost Foam

Abstract A novel multiphase flow model is presented for describing the pyrolisis of polymeric foam material in a lost foam casting process. FLOW-3D software (Flow Science, Inc.) has been used to simulate liquid metal filling dynamics and the molten metal-polymeric foam interface velocity in foam patterns of rectangular shape. The effect of the degradation gaseous products on the molten metal-polymeric foam interface velocity was taken into consideration through specially written sub-routing program. The results of the simulations are compared with the previously obtained experimental data for the lost foam iron casting.

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