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Simulation of the Moulding Process of Bentonite-Bonded Green Sand

Dheya Abdulamer A. Kadauw

Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 67-73 | DOI: 10.24425/afe.2021.136080

Keywords Green sand mould Moulding process COMSOL Multiphysics Time-dependent study

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Abstract

Finite Element Method FEM via commercially available software has been used for numerical simulation of the compaction process of bentonite-bonded sand mould. The mathematical model of soil plasticity which involved Drucker-Prager model match with Mohr-Coulomb model was selected. The individual parameters which required for the simulation process were determined through direct shear test based on the variation of sand compactability. The novelty of this research work is that the individual micro-mechanical parameters were adopted depend on its directly proportional to the change of sand density during the compaction process. Boundary conditions of the applied load, roller and fixed constraint were specified. An extremely coarse mesh was used and the solution by time-dependent study was done for investigation of material-dependent behaviour of green sand during the compaction process. The research implemented also simulation of the desired points in sand mould to predict behaviour of moulding process, and prevent failure of the sand mould. Distance-dependent displacement and distance-dependent pressure have been determined to investigate the effective moulding parameters without spent further energy and cost for obtaining green sand mould. The obtained numerical results of the sand displacement show good agreement with the practical results.

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Authors and Affiliations

Dheya Abdulamer

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ORCID:

A. Kadauw

1 2

IMKF. TU - Bergakademie Freiberg, Germany
Salahddin University-Erbil, Iraq

Optimizing Sand Moulding Process through Regression Models and Destructive Testing

Dheya Abdulamer

Archives of Foundry Engineering | 2023 | vol. 23 | No 4 | 163-168 | DOI: 10.24425/afe.2023.148959

Keywords Green sand mould Moulding parameters design of experiments Destructive tests regression methods

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Abstract

The main objective of the present study is enhanced of the sand moulding process through addressing the sand mould defects and failures, ultimately lead to improve production of the sand castings with well-defined of pattern profiles. The research aimed to reduce the cost and energy expenditure associated with the compaction time of the sand moulding process. Practical destructive tests were conducted to assess properties of the green sand moulds. Linear regression and multi-regression methods were employed to identify the key factors influencing the sand moulding process. The proposed experimental destructive tests and predicted regression methods facilitated measurement of the green sand properties and enabled evaluation of the effective moulding parameters, thereby enhancing the sand moulding process. Factorial design of experiments approach was employed to evaluate effect of parameters of water content and mixing time of the green sand compaction process on the mechanical properties of green sand mould namely the tensile strength, and compressive strength.

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Bibliography

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Authors and Affiliations

Dheya Abdulamer

e-mail:

ORCID:

University of Technology- Iraq

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Simulation of the Moulding Process of Bentonite-Bonded Green Sand

Abstract

Bibliography

Authors and Affiliations

Optimizing Sand Moulding Process through Regression Models and Destructive Testing

Abstract

Bibliography

Authors and Affiliations