Modeling and Simulation of the Casting Process with Skeletal Sand Mold
1
School of Materials Science and Engineering, Key Laboratory for Advanced Materials Processing Technology, Tsinghua University, Beijing 100084, China
2
School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China
*
Author to whom correspondence should be addressed.
Materials 2020, 13(7), 1596; https://doi.org/10.3390/ma13071596
Received: 28 February 2020
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Revised: 21 March 2020
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Accepted: 24 March 2020
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Published: 31 March 2020
The author-proposed skeletal sand mold, which mainly includes a shell, air cavities and a truss support structure, has been experimentally proven to be very useful in controlling the cooling of casting at local areas and at different periods of the casting process. The modeling and simulation of the casting process using a skeletal sand mold were systemically analyzed. Complicated casting/mold and mold/air boundaries, and the thermal and mechanical behavior of the skeletal sand mold during the casting process were highlighted. A numerical simulation of the casting process of a stress frame specimen using a skeletal sand mold was performed. The temperature, stress and displacement fields of the casting and skeletal sand mold were obtained and compared with those using a traditional sand mold. The simulated results were validated with experiments. Using the skeletal sand mold, the cooling rate of the casting can be greatly improved due to the significant heat release from mold surface to environment. The residual stress and deformation of the casting can be reduced because of the decreased stiffness of this kind of mold. Although the skeletal sand mold is susceptible to cracking, it can be avoided by filleting in the conjunctions and increasing the shell thickness.
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Keywords:
skeletal sand mold; casting; modeling and simulation; heat transfer; stress
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MDPI and ACS Style
Kang, J.; Wang, J.; Shangguan, H.; Zheng, L.; Deng, C.; Hu, Y.; Yi, J. Modeling and Simulation of the Casting Process with Skeletal Sand Mold. Materials 2020, 13, 1596. https://doi.org/10.3390/ma13071596
AMA Style
Kang J, Wang J, Shangguan H, Zheng L, Deng C, Hu Y, Yi J. Modeling and Simulation of the Casting Process with Skeletal Sand Mold. Materials. 2020; 13(7):1596. https://doi.org/10.3390/ma13071596
Chicago/Turabian StyleKang, Jinwu, Jiwu Wang, Haolong Shangguan, Lele Zheng, Chengyang Deng, Yongyi Hu, and Jihao Yi. 2020. "Modeling and Simulation of the Casting Process with Skeletal Sand Mold" Materials 13, no. 7: 1596. https://doi.org/10.3390/ma13071596
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