Method and apparatus for simulation of the filling process of casting molds

摘要

A method for simulating the flow of metal into a mould, and displaying and optimising said flow by altering the casting system in the case of gravity casting, or the parameters to be applied in the case of so-called counter-gravity casting, particularly controlled low-pressure casting with a vacuumised mould, is disclosed. According to the method, the material being simulated is replaced with a liquid that has the same density and viscosity at room temperature as said material does at its usual casting temperature (720-780 °C). The apparatus provided for carrying out said method includes a sealed vessel (1) containing the simulation liquid (2), a transparent mould (3) under a vacuum chamber (4), a tube (5) connecting the liquid supply to the mould, a measurement sensor (6) in the liquid in the vessel, a vessel and pump assembly (7) for feeding the various simulation liquids into the vessel, a set of special valves (8, 9, 10) for pressurising, decompressing and vacuumising the vessel or the chamber, and a computer (11) for receiving data from the various sensors and transmitting commands to actuators to ensure compliance with the casting parameters input into the computer. The apparatus is useful for displaying the flow, filming and analysing turbulence, and altering the casting parameters (vacuum, pressure, time) to achieve an optimal flow. The parameters are then applied to the real metal casting machine. Both apparatuses, i.e. the simulation apparatus and the real casting machine, share the same pressurising, compression, vacuumising and control lines.