Characterization of the Parameters of Sand Moulds in Compaction Process by Use of the Industrial Computer Tomography (ICT)

Abstract

One main problem in moulding is the proper characterization of the local density of the mould, the best without its destroying, for assessment the quality of the mould and to compare results of compaction modeling with experimental results. Industrial computer tomography (ICT) is a technique that allows the non-destructive and contact-free visualization and characterization of the internal and external parts of physical objects including also sand moulds. It is possible to apply ICT technique for the specific research presented here. Moulding sand compaction plays an important role for the quality of the mould and as the consequence for the quality of manufactured casting. The required quality of the castings can be achieved by selecting optimum manufacturing process parameters. The determination of these parameters is often carried out by trial-and-error-method, which is expensive and time consuming. To improve the understanding of the influence of various parameters, mathematical modeling of the compaction processes using numerical solutions was performed. Theoretical results of the compaction simulations have then been compared with practical results of mould compaction obtained by ICT. It was found that simulation results agree well with data from computer tomography and provide insight into the spatial distribution of the density of sand moulds under industrial condition.Keywords: Industrial computer tomography, sand castings, computer simulation of compaction Podstawowym problemem w procesie formowania jest prawidłowe określenie rozkładu gęstości w formie, najlepiej metodami nieniszczącymi, w celu oceny jakości formy oraz w celu porównania wyników modelowania procesu zagęszczania z wynikami eksperymentu. Przemysłowa tomografia komputerowa -ICT jest techniką, która umożliwia nieniszczącą oraz bezkontaktową wizualizację oraz charakterystykę wewnętrznych oraz zewnętrznych części obiektów fizycznych, w tym również form odlewniczych. ICT jest możliwe do zastosowania w specyficznych badaniach opisanych poniżej. Zagęszczanie masy formierskiej istotnie wpływa na jakość formy i w konsekwencji na jakość wytwarzanych odlewów. Wymagana jakość odlewów może być osiągnięta przez wybór optymalnych parametrów procesu wytwarzania. Określenie tych parametrów często jest dokonywane metodą prób i błędów, co jest kosztowne i czasochłonne. W celu lepszego zrozumienia wpływu różnorodnych parametrów zastosowano matematyczne modelowanie procesu zagęszczania. Wyniki symulacji porównano z wynikami badań zagęszczenia form z zastosowaniem metody ICT. Wykazano zgodność wyników modelowania oraz wyników pomiarów (ICT), co umożliwia określenie przestrzennego rozkładu gęstości w formie piaskowej w warunkach przemysłowych.

Study of the evolution of transport properties induced by additive processing sand mold using X-ray computed tomography

“…In this sense, some works were performed earlier by (Degruyter et al, 2010) combining LBM and X-ray µ-CT for the calculation of permeability of volcanic pumices. (Kadauw, 2014) characterized the local density of sand mold using industrial computed tomography, and found good agreement with the experimental density of sand mold. Some typical results were reported recently by (Sivarupan et al, 2018) for the use of X-ray µ-CT to characterize the additively processed porous structure like 3DP sand mold.…”

Evaluation of the Possibility of Applying Spatial 3D Imaging Using X-Ray Computed Tomography Reconstruction Methods for Quantitative Analysis of Multiphase Materials / Rentgenowska Analiza Ilościowa Materiałów Wielofazowych Z Wykorzystaniem Przestrzennego Obrazowania (3D) Przy Użyciu Metod Rekonstrukcji Tomografii Komputerowej

“…Numerous research works [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17] and the documents of the VDI/VDE 2630 association from the year 2009 [17] allow only for the determination of the accuracy associated with the geometry measurement errors, scanning errors, determination of scan resolution or dimensions-material dependence.…”

“…In addition to the typical manufacturing applications, 3D techniques are also widely used in laboratory structural studies [1][2][3][4][5][6][7][8][9][10], qualitative and quantitative analysis [6][7][8][9][10], or other high-speed measurements of specific materials' properties, made for the sole purpose of manufacturing processes. The versatility of these research methods allows its use in many industries, from timber industry (quality assessment of wood at sawmills) [4], to the highly specialized electrotechnic and electronic companies [2], to medical applications [5].…”