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Simulation of mould filling in lost foam casting process

Mirbagheri, S. M. H ; Sharif University of Technology | 2003

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  1. Type of Document: Article
  2. DOI: 10.1080/13640461.2003.11819635
  3. Publisher: Maney Publishing , 2003
  4. Abstract:
  5. In this investigation, an algorithm was developed to calculate the gas pressure at the melt/foam interface (gap) owing to degraded foam during mould filling in the lost foam casting process (LFC). The effect of back-pressure on mould filling was modelled using a new experimental function by the addition of a three-dimensional volume of fluid (3D-VOF) function. The molten flow and free surface were simulated using the solution algorithm-VOF (SOLA-VOF) numerical technique. To simulate the three-dimensional incompressible flow in the LFC, the pressure boundary conditions, heat transfer and foam gas pressure effect were modified. Finally, in order to verify the computational results of 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, then images were analysed frame-by-frame to obtain foam depolymerisation and gap volume during mould filling. The comparison of experimental and numerical results in the LFC filling sequence showed good agreement, which confirms the accuracy of the model. © 2003 W. S. Maney & Son Ltd
  6. Keywords:
  7. ASOLA-VOF technique ; Donor-acceptor cells ; Fluid flow simulation ; Foam degradation ; Free surface ; High-speed camera photography ; Lost foam casting
  8. Source: International Journal of Cast Metals Research ; Volume 16, Issue 6 , 2003 , Pages 554-565 ; 13640461 (ISSN)
  9. URL: https://www.tandfonline.com/doi/abs/10.1080/13640461.2003.11819635