Abstract
Problem statement: The solidification of materials depends on the cooling rate of the materials which is governed by heat flow in the mould and alloy composition. Solidification rate also affects the structure and properties of the materials. Approach: In the present study, the heat flow of cold set resin bonded sand mould was simulated using JL Analyzer FEM analysis software. To verify the model, the gray cast iron was melted at 1350°C temperature and poured into a resin bonded sand mould at 1300°C. Results: It showed that most of the heat-reserve at the junction of the mould which was nearer to the source of liquid metal and the lowest heat-reserve at the end of the mould. So, the solidification rate was very high at the end of the mould wall whereas it was comparatively low near the sprue of the mould. Conclusion: Finally, depending on the heat-flow through the mould, the solidification rate changed the microstructure from chill, mottled and gray cast iron and hardness changed from 95.1 HRB-78.78 HRB.
Highlights
Casting is the most important process in manufacturing and sand casting is the most convenient process in foundry
Solidification rate of molten metal in the sand mould depends on the thermal conductivity of the mould material, casting design and the direction of heat-flow into the mould wall
The whole study divides into two parts; firstly, the prediction of heat flow through the mould wall and secondly, through the casting of gray cast iron
Summary
Casting is the most important process in manufacturing and sand casting is the most convenient process in foundry. Heat-flow through the sand mould was studied by many researchers (Seetharamu et al, 2001; Pequet et al, 2002; Sulaiman and Hamouda, 2004; Mirbagheri et al, 2004; Lee and Lee, 2005; Kulkarni and Radhakrishna, 2007; Kermanpur et al, 2008; Hsu et al, 2009; Fras et al, 2005a; 2005b; Collini et al, 2008). Sulaiman and Hamouda (2004) investigated the thermal history of the sand casting process for mould filling time using FORTRAN They have shown that the lastly solidifying area is near the junction. Fras et al (2005a; 2005b) studied on the transition from gray to white during solidification for both mathematically and experimentally They conclude that solidification rate depends on the modulus of the casting and the heat flow through the mould that is molding materials
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