Abstract
Core shooting process is the most widely used technique to make sand cores and it plays an important role in the quality of sand cores as well as the manufacture of complicated castings in metal casting industry. In this paper, the flow behavior of sand particles in the core box was investigated synchronously with transparent core box, high-speed camera, and pressure measuring system. The flow pattern of sand particles in the shooting head of the core shooting machine was reproduced with various colored core sand layers. Taking both kinetic and frictional stress into account, a kinetic-frictional constitutive correlation was established to describe the internal momentum transfer in the solid phase. Two-fluid model (TFM) simulations with turbulence model were then performed and good agreement was achieved between the experimental and simulation results on the flow behavior of sand particles in both the shooting head and the core box. Based on the experimental and simulation results, the flow behavior of sand particles in the core box, the formation of “dead zone” in the shooting head, and the effect of drag force were analyzed in terms of sand volume fraction (αs), sand velocity (Vs), and pressure variation (P).
Highlights
Core shooting process is the most widely used technique to make sand cores and has attracted continuous attention in metal casting industry with the increase of the demands, complexity, and high quality requirements of castings [1]
There is a definite need for a detailed analysis of the flow dynamics of core shooting process
In order to facilitate the analysis of flow dynamics, the core box was designed to be a simple shape with multiple changes of flow direction
Summary
Core shooting process is the most widely used technique to make sand cores and has attracted continuous attention in metal casting industry with the increase of the demands, complexity, and high quality requirements of castings [1]. Simple in its concept, the effective use of core shooting process still faces some challenges. Performance of the core shooting process and the quality of the sand cores are strongly affected by the operative conditions. The mechanisms governing the complex flow behavior of sand particles in core shooting process is still unclear and until now trial-and-error method is still the main method to produce sand cores. The efficiency and quality of core shooting process is low and lots of waste core sands are generated. There is a definite need for a detailed analysis of the flow dynamics of core shooting process
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