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Modeling and Simulation of Heat Transfer Phenomenon Related to Mold Heating during Investment Casting

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Document pages: 24 pages

Abstract: Cast shape during investment casting process dictates properties and service life of the casting. These properties are the function of cast part parameters (both static and dynamic), part geometry and hence mold geometry, nature and type of metal being cast, properties (extrinsic and intrinsic) and processing parameters (rate of heating, rate of cooling, rate of pouring). Improper and inadequate manipulation and modification of mold properties degrade the properties and life of casting altogether. A mathematical model is developed using standard transport equations incorporating all heat transfer coefficients (HTCs) to determine the effect of external mold heating on the properties of the final casting and a simulation is performed in C++ to validate it against experimental results. Pure iron is casted in investment molds of silica sand with zircon coating. Airflow near the mold surfaces was partially restricted due to geometry of the molds and arrangement of the pieces around a tree. The variations in heat transfer coefficient contribute towards total heat transfer out of mold surface. External heating is found to be very effective for improved casting properties. The mold heat transfer profile is found to be in good agreement with experimental values validating the effectiveness of mold heating.

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