Optimising of Moulding Parameters for Green Sand Compaction by Computer Simulation and a New Compaction Measuring Device

Abstract

The quality of castings produced by green sand moulds depends strongly on the compaction of the moulding sand. The moulding process parameters of green sand directly affect casting quality, energy consumption and cycle time. Unnecessary holding periods during particular compaction process steps increase the cycle time and also cause higher energy consumption. The determination of optimal compaction parameters is often carried out by trial-and-error which is expensive and time consuming. To improve this situation, the process of compaction is calculated using a mathematical model and the finite element method (FEM). For the validation of the calculated and experimental data the computer tomography method was used. The effect of different moulding parameters was examined using a new sensor. During mould compaction the sand density in different regions of the mould was recorded over time. These results allow foundry personnel to monitor, adjust and optimise the moulding process.