Abstract
Inorganically-bound sand cores are used in many light-metal foundries to form cavities in the cast part, which cannot be realised by the mould itself. To enable FEM simulations with core materials, their mechanical properties have to be measured. In this article, we adapt methods to determine the Young’s and shear modulus, the Poisson ratio and the fracture strain of sand cores. This allows us to fully parametrise an ideal brittle FEM model. We found that the Young’s and shear modulus can be obtained acoustically via the impulse excitation technique. The fracture strain was measured with a high-speed camera and a digital image correlation algorithm.
Highlights
A rising number of light-metal foundries are using inorganically-bound core materials instead of organically-bound ones, due to stricter environmental laws and the need for eco-friendly production processes [1]
The cores consist of sand and a binder agent, which holds the individual particles together and forms a porous material, which can be used for foundry moulds and cores [3]
We propose to parametrise future FEM simulations with a fracture strain calculated from acoustical determined elastic parameters and a fracture stress, which is corrected by the factor 0.8 determined in this article
Summary
A rising number of light-metal foundries are using inorganically-bound core materials instead of organically-bound ones, due to stricter environmental laws and the need for eco-friendly production processes [1]. The cores consist of sand and a binder agent, which holds the individual particles together and forms a porous material, which can be used for foundry moulds and cores [3]. Inorganic sodium silicate binders (waterglass) do not combust during the casting, while organic binders emit a number of hazardous combustion products. The absence of a combustion process means that more binder remains in the cast-in sand core. The sand cores have to be removed via high-energy hammer impacts to the cast component, which is called de-coring [4]
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