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Optimisation of mould and core quality and materials usage in the metal castings industry

Deliverables

The availability of the software programme will allow the consolidation of the knowledge base. This is currently developed over experience on a trial and error basis with loss of knowledge when personnel leave the industry. The possibility of simulation to evaluate the effects of performance will allow the development of a more fundamental knowledge base by combining simulation with practice.
A continuum mathematical model has been developed to simulate the flow of sand particles and validated on 2D examples. These models have been simplified and integrated in the PAMCAST software to provide an industrial solution for the modelling of core sand blowing. Results obtained with the software have been validated against experimental data showing the effect of geometry and venting arrangement.
By the process of applying the best practice operation and the use of simulation techniques, the method of corfe making can be optimised to reduce material consumption. Techniques provide a method where by the combination of the results from the project can be used to achieve right first time manufacture and reduced material usage.
The development of mathematical models to simulate the flow of gas/air through a sand media have been developed and validated on simple test cases using data input from the proving test methods. The integration of these models in the commercial PAMCAST software is now available in order to provide an industrial solution for gassing and purging of sand cores and moulds.

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