Modeling and Simulation of the Casting Process with Skeletal Sand Mold

Area of Science:

• Materials Science
• Manufacturing Engineering
• Casting Technology

Background:

• Traditional sand molds present challenges in controlling casting cooling rates and can lead to significant residual stress and deformation.
• Optimizing casting processes requires advanced mold designs that offer localized control over thermal and mechanical behaviors.

Purpose of the Study:

• To investigate the effectiveness of a novel skeletal sand mold in controlling casting cooling and reducing defects.
• To analyze the thermal and mechanical performance of the skeletal sand mold during the casting process through modeling and simulation.

Main Methods:

• Systematic analysis of modeling and simulation for casting processes using a skeletal sand mold.
• Numerical simulation of casting a stress frame specimen, focusing on temperature, stress, and displacement fields.
• Experimental validation of simulated results for skeletal sand mold performance compared to traditional sand molds.

Main Results:

• The skeletal sand mold significantly improves casting cooling rates due to enhanced heat dissipation to the environment.
• Reduced mold stiffness in the skeletal sand mold leads to decreased residual stress and deformation in the casting.
• Experimental validation confirmed the simulated improvements in cooling and stress reduction.

Conclusions:

• The skeletal sand mold offers a viable method for enhancing casting quality by controlling cooling and minimizing defects.
• While susceptible to cracking, design modifications like filleting and increased shell thickness can effectively prevent this issue.
• This advanced mold technology holds potential for improving efficiency and quality in casting applications.