Development of Mathematical Relationships for Calculating Material-Dependent Flowability of Green Molding Sand
- 32 Downloads
Flowability property has a strong influence on the performance of the molding process of green sand. Flowability is the capability of bentonite-bonded green sand for flowing around a model especially in the critical regions during the sand mold-making process. It is a necessary property for obtaining molds without bridge formation and without loss of the energy consumed in the molding process. The old methods are destructive tests usually carried out for measuring flowability of green sand before an actual molding process. Direct tests during the mold-making process are not implemented yet. The new method developed by Bast (Arch Metall Mater 58(3):946–952, 2013) uses two sensors. These sensors are integrated into the template similar to the template of the Orlov test (Mori and Inui in J Jpn Foundrym Soc 44(8):659–666, 1972) for live monitoring of flowability of green sand during molding process. Four mathematical mechanisms have been developed for determining material-dependent flowability based on the sensor’s signals. Effect of compactability, water content and speed of pressing machine on the flowability of bentonite-bonded green sand has been studied.
Keywordscontact area continuous pressure green sand mold material-dependent flowability stationary old methods
The author Dheya Abdulamer wants to thank, in particular, the valuable advices, important discussions, encouragement and useful hints from Prof. Bast, technician Mr. Engmann, Prof. Hentschel, and Prof. Zeidler.
- 1.U.S. Department of Energy, Metal casting, Industry of the future, 2002 annual report. http://www1.eere.energy.gov/manufacturing/resources/metalcasting/pdfs/annual2002.pdf. Accessed 08 June 2018.
- 2.C.H. Benson and S. Bradshaw, User guideline for Foundry Sand in Green Infrastructure Construction, University of Wisconsin-Madison, Madison, 2011Google Scholar
- 3.P.D. Webster, Fundamentals of Foundry Technology, Portcullis Press Publication, Redhill, 1980, p 404–408Google Scholar
- 6.H.G. Levelink, H. van den Berg, and E. Frank, Criterion of molding sand quality for modern molding machines, Foundry Publ., 1975, 62, p 1 (in Germanian)Google Scholar
- 7.R.H. Khan, N.S. Mahadevan, and M.R. Seshadri, Some Studies on the Flowability of Moulding Sand, Indian Institute of Science, Bangalore, 1972 (in English)Google Scholar
- 9.F. Hofmann, Clay-Bonded Moulding Sands, Foundry Publishing, Düsseldorf, 1975 (in Germanian)Google Scholar
- 10.A. Malaschkin, Development of a Method for the Continuous Quality Control of the Green Sand Molding Process with Automatic Molding Machines, Ph.D. Dissertation, TU-Bergakademie Freiberg, 2002 (in Germanian)Google Scholar
- 11.A. Kadauw, J. Bast, D. Fiedler, I. Betchvaia, and H.C. Saewert, Computer simulation of squeeze moulding and validation of results using Industrial Computed Tomography (ICT), Arch. Metall. Mater., 2007, 52(3), p 447–451 (in English)Google Scholar
- 12.E. Flemmming and W. Tilch, Mold Sand Materials and Molding Processes, German Publisher of basic industry, Leipzig, 1993 (in Germanian)Google Scholar
- 13.R. Schwarze, J. Bast, W. Tilch, A. Rudert, W. Simon, and H. Belfaqir, Modeling of Flowing Process of Core Molding Sand as non-Newtonian Fluid Flow, DFG-Project, TU-Bergakademie Freiberg, Freiberg, 2008 (in Germanian)Google Scholar
- 14.W.F. Chen and E. Mizuno, Nonlinear Analysis in Soil Mechanics-Theory and Implementation, Elsevier, Amsterdam, 1990Google Scholar
- 15.E. Abdullah, Investigations between Stresses and Stresses Distribution at Fabrication of Clay-Bounded Molds, Ph.D Thesis, TU-Bergakademie Freiberg, 2014 (in Germanian)Google Scholar
- 16.A. Kadauw, Mathematical Modelling of Compaction Processes of Molding Sand, Ph.D. Dissertation, TU-Bergakademie Freiberg, 2006 (in Germanian)Google Scholar
- 17.M. Mori and S. Inui, Green mold characteristics of bentonites and their deterioration on repeated usage, J. Jpn. Foundrym. Soc., 1972, 44(8), p 659–666 (in Japanese)Google Scholar