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Influence of Different Types of Green Mold Sand for Casting a Brake Disk, Evaluation by CFD Simulation

2022; Springer Science+Business Media; Linguagem: Inglês

10.1007/978-3-031-08280-1_9

1876-1119

Marco Vinicio Carrión Vargas, Diana Peralta-Zurita, Jaime Vinicio Molina Osejos,

Metallurgy and Material Science

In the field of metal casting, several studies have been carried out to seek an improvement in the properties of molding mixtures for green sand molding, with the aim of reducing their impact on the occurrence of defects in the final elements, however in this study, the influence of the type of sands has been indirectly evaluated. The present research work aims to evaluate the influence of the type of sand in the filling process of a casting mold, using Altair’s Hyperworks CFD simulation for a break disc mold. The methodology started from the CAD model of the brake disc of a Chevrolet Aveo Sonic 1.6 vehicle of the models between years 2012 and 2014. A second input element was the sand tests from the specialized laboratory. Subsequently the simulation of the sand filling process was carried out inside the mold, separated into a lower and an upper mold. As a result, simple regression curves were obtained that show the relationship between: Eddy’s viscosity, pressure, surface film coefficient, and the density of the molding sand. For the validation, the simulation of the pouring of the liquid metal into the casting mold was carried out, from which, as an important contribution, the solidification profiles of the brake disc were obtained. As a conclusion of the present work, it was determined that the fineness index of the molding sand has a direct influence on the compaction pressure, and the laminar nature of the flow of the sand into the mold.