Effect of sand mold models on the simulated mold restraint force and the contraction of the casting during cooling in green sand molds

Yuki Inoue, Yuichi Motoyama, Hiroki Takahashi, Keita Shinji, Makoto Yoshida

    Research output: Contribution to journalArticle

    12 Citations (Scopus)

    Abstract

    In this work, the JIS AD12.1 (almost the same as A383.1) aluminum alloy was cast in a green sand mold. The restraint force from the sand mold and the contraction of the casting were measured dynamically from the solidifying temperature to the shake-out temperature using a dedicated device. Then, FEM (Finite Element Method) thermal stress analyses of the experiment were performed. The analyses adopted four types of representative constitutive equations and the mechanical properties of the green sand mold, which were quoted from previous research articles. As verification, this study dynamically compared the simulated restraint force and the contraction of casting with measured results and examined which mechanical properties are important for expressing the restraint force of the sand mold. This verification is the first attempt in the world. As a result, the simulated restraint force was estimated to be over ten times as large as the measured result in each type of equation because the yield stress of the sand mold used in our experiment was lower than those quoted from previous studies. The yield stress measured by a uniaxial compression test was 1/20 of the quoted values. When the measured yield stress was adopted in the simulation, the simulated restraint force and contraction approached the measured results. The yield stress of the sand mold was a dominant factor in the restraint force simulated by the thermal stress analyses. The yield stress of the green sand mold used in the casting process should be measured to predict the residual stress using FEM thermal stress analyses.

    Original languageEnglish
    Pages (from-to)1157-1165
    Number of pages9
    JournalJournal of Materials Processing Technology
    Volume213
    Issue number7
    DOIs
    Publication statusPublished - 2013

    Fingerprint

    Molds
    Casting
    Cooling
    Contraction
    Yield Stress
    Sand
    Yield stress
    Thermal Stress
    Thermal stress
    Mechanical Properties
    Model
    Finite Element Method
    Finite element method
    Mechanical properties
    Aluminum Alloy
    Residual Stress
    Constitutive Equation
    Constitutive equations
    Experiment
    Aluminum alloys

    Keywords

    • Aluminum alloy
    • FEM
    • Residual stress
    • Sand casting
    • Sand mold
    • Thermal stress analysis

    ASJC Scopus subject areas

    • Computer Science Applications
    • Modelling and Simulation
    • Ceramics and Composites
    • Metals and Alloys
    • Industrial and Manufacturing Engineering

    Cite this

    Effect of sand mold models on the simulated mold restraint force and the contraction of the casting during cooling in green sand molds. / Inoue, Yuki; Motoyama, Yuichi; Takahashi, Hiroki; Shinji, Keita; Yoshida, Makoto.

    In: Journal of Materials Processing Technology, Vol. 213, No. 7, 2013, p. 1157-1165.

    Research output: Contribution to journalArticle

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