Measurement of Metal Velocity in Sand Casting during Mold Filling
Measurement of Metal Velocity in Sand Casting during Mold Filling
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DOI：
10.3390/met9101079
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发表时间：
2019-10-01
期刊：
影响因子：
2.9
通讯作者：
Manogharan, Guha
中科院分区：
文献类型：
--
作者：
Sama, Santosh Reddy;MacDonald, Eric;Manogharan, Guha
充型过程中的熔体湍流对砂型铸件的质量是不利的。在这项研究中，作者提出了一种嵌入物联网（IoT）传感器的新方法，以监测金属铸造过程中砂型中的实时熔体流动速度。型腔被整合在砂模中，以精确定位传感器。电容式和磁式传感器嵌入腔内，通过振荡器计算熔体流动速度，振荡器的频率分别对近场介电常数和磁通量的变化敏感。通过将传感器集成到3D砂打印（3DSP）模具中，用于圆锥螺旋和直浇口配置，以测量铝合金319的流动速度，从而研究了传感器的效率。实验熔体流动速度与计算模拟估计的误差在5%以内。3DSP的一个主要优点是，在3DSP处理过程中，复杂浇注系统的几何自由度可以减少湍流和传感器集成所需的模具体积。本研究的结果为在砂型中嵌入物联网传感器来监测金属速度提供了机会，以验证模拟结果（2-5%的误差），比较浇注系统的性能，并改善人工浇注作为质量控制系统的铸造实践。
Melt turbulence during mold filling is detrimental to the quality of sand castings. In this research study, the authors present a novel method of embedding Internet of Things (IoT) sensors to monitor real-time melt flow velocity in sand molds during metal casting. Cavities are incorporated in sand molds to position the sensors with precise registration. Capacitive and magnetic sensors are embedded in the cavities where melt flow velocity is calculated by using an oscillator, the frequency of which is sensitive to changes in the close field permittivity, and change in magnetic flux, respectively. Their efficiency is investigated by integrating the sensors into 3D sand-printing (3DSP) molds for conical-helix and straight sprue configurations to measure flow velocities for aluminum alloy 319. Experimental melt flow velocities are within 5% of estimations from computational simulations. A major benefit of 3DSP is the geometrical freedom for complex gating systems necessary to reduce turbulence and access to mold volume for sensor integration during 3DSP processing. Findings from this study establish the opportunity of embedding IoT sensors in sand molds to monitor metal velocity in order to validate simulation results (2-5% error), compare gating systems performance, and improve foundry practice of manual pouring as a quality control system.