A benchmark experiment of the mold filling of a cast iron plate by lost foam casting

Jinwu Kang, Xiao Ha, G. Nie, H. Long, Tianjiao Wang, Yong-yi Hu
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Abstract

In lost foam casting (LFC), the presence of an expanded polystyrene (EPS) inside the mold leads to new features for the filling of the melt. The burning of the EPS pattern has great effect on its filling. To provide benchmark experiments for the modeling and numerical simulation of the mold filling process for LFC, a vertical plate with a window was selected. The window was designed in variation of sizes and distances to the borders so as to investigate the melt filling of a series of narrow paths in LFC. The designed EPS pattern were made and the corresponding molds were prepared and melt cast iron was poured. The measurement system of liquid metal filling based on modified contact time method (METM) was used. The filling of measured points was illustrated by an array of light-emitting diodes (LED) arranged resembling the shape of the casting, with the lightening of each diode representing the filling time instant of the measurement point. The filling times of all the points were obtained by the image analysis of recorded movie. The filling profiles and filling velocity during filling process were obtained. The filling results provide support for numerical simulation of LFC. Keywords: Lost foam casting (LFC), mold filling, modified contact time method, LED display, plate casting, cast iron
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对消失模铸造铸铁板充型进行了基准试验
在消失模铸造(LFC)中,模具内膨胀聚苯乙烯(EPS)的存在导致熔体填充的新特征。EPS花纹的燃烧对其填充有很大的影响。为了给LFC充型过程的建模和数值模拟提供基准实验,选择了带窗的垂直板。设计了不同尺寸和距离的窗口,以研究LFC中一系列狭窄路径的熔体填充。制作了设计的EPS图案,制备了相应的模具,浇注了熔体铸铁。采用了基于修正接触时间法(METM)的液态金属填充量测量系统。测量点的填充由一组类似铸件形状的发光二极管(LED)来表示,每个二极管的点亮表示测量点的填充时间瞬间。通过对记录的影像进行分析,得到各点的填充时间。得到了充填过程中的充填曲线和充填速度。充填结果为LFC的数值模拟提供了依据。关键词:消失模铸造(LFC),充型,修改接触时间法,LED显示屏,板材铸造,铸铁
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