Effect of Vibrational Modes on Sand Pressure and Pattern Deformation in the EPC Process

During the EPC (expendable pattern casting) process, one of the essential requirements is to prevent pattern distortion duringsand filling and compaction. A new method which vibrates the system in a two-dimensional circular mode has been appliedto the EPC process. The molding properties of unbonded sand obtained by this new vibration mode are investigated andcompared with those in the one-dimensional vertical mode. For adequate compaction of sand. the circular vibration mode ismore effective than the vertical mode. Sand became more fluidized by the circular vibration and the particle pressure coefficientwas close to unity The particle pressure coefficient, which is defined as the ratio of horizontal to vertical sand pressure, isresponsible for the effectiveness of sand filling.

3D numerical simulation of high pressure squeezing process with revised Drucker-Prager/Cap model

In order to investigate the sand mold strength after the aeration sand filling-high pressure squeeze moldingprocess,a tree-dimentional(3D)numerical simulation was introduced.The commercial finite element method(FEM)software ABAQUScombined with a revised Drucker-Prager/Cap model was used to simulate the squeeze compaction process.Additionally,the sand bulk density after the aeration sand filling process was tested by a specially designed experiment,which divided the whole sand bulk in the molding chamber into5x9regions and it was used as the input to simulate the squeeze process.During the simulation process,the uniform modeling simulation and the patition modeling simulation methods were used a d the3D numercal simulation results were compared with correlative benchmark testings.From the3D numerica simulation results,it can be concluded that the uniform sand bulk density distribution can obtain a high quality sandmold and the revised Drncker-Pager/Cap model is suitable for handling the situation with the complex paaern.The3D numerical simulation results can predict well the sand mold strength distribution and can be used as guidelines for the production practice.

Microstructure and anisotropic swelling behaviour of compacted bentonite/sand mixture

Pre-compacted elements （disks, tutus） of bentonite/sand mixture are candidate materials for sealing plugs of radioactive waste disposal. Choice of this material is mainly based on its swelling capacity allowing all gaps in the system to be sealed, and on its low permeability. When emplaced in the gallery, these elements will start to absorb water from the host rock and swell. Thereby, a swelling pressure will develop in the radial direction against the host rock and in the axial direction against the support structure. In this work, the swelling pressure of a small scale compacted disk of bentonite and sand was experimentally studied in both radial and axial directions. Different swelling kinetics were identified for different dry densities and along different directions. As a rule, the swelling pressure starts increasing quickly, reaches a peak value, decreases a little and finally stabilises. For some dry densities, higher peaks were observed in the radial direction than in the axial direction. The presence of peaks is related to the microstructure change and to the collapse of macro- pores. In parallel to the mechanical tests, microstructure investigation at the sample scale was conducted using microfocus X-ray computed tomography （BCT）. Image observation showed a denser structure in the centre and a looser one in the border, which was also confirmed by image analysis. This structure heterogeneity in the radial direction and the occurrence of macro-pores close to the radial boundary of the sample can explain the large peaks observed in the radial swelling pressure evolution. Another interesting result is the higher anisotropy found at lower bentonite dry densities, which was also analysed by means ofμCT observation of a sample at low bentonite dry density after the end of test. It was found that the macro-pores, especially those between sand grains, were not filled by swelled bentonite, which preserved the anisotropic microstructure caused by uniaxial compression due to the absence of microstructure collapse.