NUMERICAL SIMULATION OF CASTING'S MOLD FILLING PROCESS

Numerical simulation of casting＇s mold filling process is the main and the most important aspect of the foundry CAE technology. But it is time-consuming; it may take dozens of hours or several days. While with the development of computer hardware, numerical simulation of casting＇ s mold filling process has made rapid progress. The simulation results, therefore, have become more and more practical. This study tries to find some clues of the computational time of mold filling process. Firstly, this paper introduces mathematic model and the basic route of numerical simulation of casting＇s mold filling process. Then the computational time of mold filling process has been carefully studied, and some new and useful results have been gained from the study of the computational time. Finally, this paper has given some real applications of numerical simulation of casting＇s mold filling process.

Optimization of clay material mixture ratio and filling process in gypsum mine goaf

Because there is neither waste rock nor mill tailings in the gypsum mine, and the buildings on the goaf of gypsum mine are needed to be protected, the research proposed the scheme of the clay filling technology. Gypsum, cement, lime and water glass were used as adhesive, and the strength of different material ratios were investigated in this study. The influence factors of clay strength were obtained in the order of cement, gypsum, water glass and lime. The results show that the cement content is the determinant influence factor, and gypsum has positive effects, while the water glass can enhance both clay strength and the fluidity of the filing slurry. Furthermore, combining chaotic optimization method with neural network, the optimal ratio of composite cementing agent was obtained. The results show that the optimal ratio of water glass, cement, lime and clay (in quality) is 1.17:6.74:4.17:87.92 in the process of bottom self-flow filling, while the optimal ratio is 1.78:9.58:4.71:83.93 for roof-contacted filling. A novel filling process to fill in gypsum mine goaf with clay is established. The engineering practice shows that the filling cost is low, thus, notable economic benefit is achieved.

Numerical simulation of mould filling process for pressure plate and valve handle in LFC

In lost foam casting (LFC), the distribution of polymer beads during the bead filling process is not uniform, and the collision between polymer beads determines the distribution of two-phase flow of gas and solid. The interaction between the gas and solid phases reveals as coupling effect of the force that gas exerts on particles or vice versa, or that among particles. The gas-solid flow in filling process is nonlinearity, which makes the coupling effect an essential point to carry out a simulation properly. Therefore, information of each particle's motion is important for acquiring the law of filling process. In bead filling process, compressed air is pressed into mold cavity, and discharged from gas vent, creating a pressure difference between outer and inner space near the gas vent. This pressure difference directly changes the spatial distribution and motion trace of gas and solid phases. In this paper, Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) are employed to simulate the fluid dynamic character based on Newton's Third Law of Motion. The simulation results of some casting products such as pressure plate and valve handle are compared with the result obtained from practical experiment in order to test the feasibility of DEM. The comparison shows that this DEM method can be a very promising tool in the mould filling simulation of beads' movement.

Characteristics and influence factors of mold filling process in permanent mold with a slot gating system

The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas.In this study,the slot gating system is employed to improve mold filling behavior and therefore,to improve the quality of aluminum castings produced in permanent molds.An equipment as well as operation procedures for real-time X-ray radiography of molten aluminum flowing into permanent molds have been developed.Graphite molds transparent to X-rays are utilized which make it possible to observe the flow pattern through a number of vertically oriented gating systems.The investigation discovers that there are many influencing factors on the mold filling process.This paper focuses its research on some of the factors,such as the dimensions of the vertical riser and slot thickness,as well as roughness of the coating layer.The results indicate that molten metal can smoothly fill into casting cavity with a proper slot gating system.A bigger vertical riser,proper slot thickness and rougher coating can provide not only a better mold filling pattern,but also hot melt into the top of the cavity.A proper temperature gradient is obtainable,higher at the bottom and lower at the top of the casting cavity,which is in favor of feeding during casting solidification.

Mensuration and simulation of mold filling process in semi-solid die-cast of aluminum alloy

To understand the flow trace of semi-solid slurry in mold cavity, some thermocouples were inserted in mold cavity, and the reaction timing of thermocouples showed the arrival of fluid. The filling time and rate were estimated by comparison between the experiment and calculation. The introduction of computer simulation technique based on ADSTEFAN was to predict injectionforming process and to prevent defects during trial manufacture of various parts. By comparing the formed appearance of parts in experiment and in simulation, and observing the relationship between internal defects inspected by X-ray or microscope and the flow field obtained in simulation, it was indicated that both have quite good agreement in simulation and experiment. Right predictions for cast defects resulted from mold rilling can be carried out and proper direction was also proposed. The realization of numerical visualization for filling process during semi-solid die-cast process will play an important role in optimizing technology plan.

Numerical simulation and analysis of mould filling process in lost foam casting

In lost foam casting(LFC)the foam pattern is the key criterion,and the filling process is crucialto ensure the high quality of the foam pattern.Filling which lacks uniformity and denseness will cause variousdefects and affect the surface quality of the casting.The influential factors of the filling process are realized in thisresearch.Optimization of the filling process,enhancement of efficiency,decrease of waste,etc.,are obtained bythe numerical simulation of the filling process using a computer.The equations governing the dense gas-solid two-phase flow are established,and the physical significanceof each equation is discussed.The Euler/Lagrange numerical model is used to simulate the fluid dynamiccharacteristics of the dense two-phase flow during the mould filling process in lost foam casting.The experimentsand numerical results showed that this method can be a very promising tool in the mould filling simulation of beads’movement.

Comparison of rheological analytic model with numerical simulation in powder injection molding filling process

Mathematical model of filling disk-shaped mold cavity in steady state was studied.And the mathematical model under vibration field was developed from the model in steady state.According to the model of filling disk-shaped mold cavity in steady state,the filling time,the distribution of velocity field and the pressure field were obtained.The analysis results from rheological analytic model were compared with the numerical simulation results using Moldflow software in the powder injection molding filling process.Through the comparison,it is found that it is unreasonable to neglect the influence of temperature when calculated the pressure changing with the time at the cavity gate,while it can be neglected in other situations such as calculating the distribution of the velocity fields.This provides a theoretical reference for the establishment of correct model both in steady state and under vibration force field in the future.

Treatment of Synovial Cysts in Relation to the Tibial Tunnel of Anterior Cruciate Ligament Grafts by Filling the Tunnel with Acrylic Cement

Introduction: Synovial cyst of the tibial tunnel in connection with anterior cruciate ligament (ACL) reconstruction is a rare but particularly troublesome complication. Medical treatment is often doomed to failure, and surgical treatment usually consists of excising the cyst and filling the tunnel with bone. The aim of this study was to evaluate the results of filling the tunnel with acrylic cement. Hypothesis: Filling the tibial bone tunnel with acrylic cement should eliminate communication between the joint cavity and the pre-tibial surface and prevent cyst recurrence. Patients and Methods: This retrospective series is composed of 13 patients, 9 men and 4 women, mean age 48.5 years (31 to 64) operated on between 2011 and 2019 for an intra- and extraosseous synovial cyst consecutive to the tibial tunnel of an ACL graft. Between 1983 and 2016, 12 of the patients had had a bone graft without bone block fixation (DI-DT or Mac Intosh) and one patient, a bone-bone transplant (KJ). The cyst was of variable size, located on the anteromedial aspect of the proximal end of the tibia, and often painful, warranting consultation. At the time of the initial operation, 9 patients had undergone meniscectomies (6 medial, 2 lateral, 1 double). In 7 knees, there were 7 cartilage lesions in the femorotibial and/or patellofemoral compartments (one stage 1 lesion, 2 stage 2 lesions, 4 stage 3 lesions, and no stage 4 lesions). Only 2 knees had neither cartilage nor meniscus lesions. After curettage of the bone tunnel /− removal of the non-resorbed or PEEK interference screw, the tunnel was filled with acrylic cement /− reinforced with a ligament staple to prevent expulsion. All patients underwent regular follow-up consultations until recovery. Results: At a maximum follow-up of 8 years, only 1 cyst recurred, representing a 7.69% failure rate. It was reoperated with another technique, which involved filling the tibial bone tunnel with bone graft taken from a half-bank head. After recovery, the cyst healed definitively. All patients were able to return to their previous activity within 15 days of surgery. Conclusion: Filling the tibial tunnel with acrylic cement reinforced /− with a ligament staple is a reliable and rapid solution for the treatment of intra- and extra-articular synovial cysts in relation to the tibial tunnel of ACL grafts.

Raw Gangue Filling Mining under Construction —A Case Study in China

In order to recover the strip pillar coal resources, reduce the amount of gangue mountain and realize remediation of the goaf environment in the old mining area, the raw gangue filling mining technology was proposed. According to the previous practical experience, the feasibility of the implementation of raw gangue filling mining technology in the coal-pressed area was analyzed. Through the filling gangue compaction test, the deformation under different loading stages was obtained. Further, a reasonable prediction of the deformation beyond the experimental limited loading load was made based on the experimental results. Through the deformation source analysis of the whole process of gangue filling, the key factors for controlling deformation before, during, and after filling were determined. Additionally, the proportion of deformation during different stages was quantified. Considering the protection of surface buildings, mining fullness of the working face and mining technology, the production parameters of 1209 and 1210 filling working faces were preliminarily determined. Through numerical simulation, the rationality of mining scheme was verified. Based on the practice of 1209 working face and the key factors to control the deformation of gangue filling, the mining system and process in 1210 working face were optimized. According to the measured surface rock movement, raw gangue filling mining technology can meet the requirements of surface building protection level. Especially, this paper provides a method to quantitatively calculate the equivalent mining height (EMH) of raw gangue filling and its mining deformation, which has reference significance for old mining areas.

Effects of mechanical vibration on filling and solidification behavior, microstructure and performance of Al/Mg bimetal by lost foam compound casting

Al/Mg bimetal was prepared by lost foam solid-liquid compound casting,and the effects of mechanical vibration on the filling and solidification behavior,microstructure and performance of the bimetal were investigated.Results show that the mechanical vibration has a remarkable influence on the filling and solidification processes.It is found that after mechanical vibration,the filling rate increases and the filling rate at different times is more uniform than that without vibration.In addition,the mechanical vibration also increases the wettability between liquid AZ91D and A356 inlays.The mechanical vibration reduces the horizontal and vertical temperature gradient of the casting and makes the temperature distribution of the whole casting more uniform.Compared to the Al/Mg bimetal without vibration,the shear strength is improved by 39.76%after the mechanical vibration is applied,due to the decrease of the inclusions and Al_(12)Mg_(17) dendrites,and the refinement and uniform distribution of the Mg_(2)Si particles in the interface of the Al/Mg bimetal.

Effects of Lodging at Different Filling Stages on Rice Yield and Grain Quality

The effects of lodging of rice plants from 20 d after full heading to maturity on yield and grain quality were investigated with a hybrid rice combination Liangyoupeijiu and a japonica rice cultivar CY-6. The results showed that, except for brown rice rate, almost all parameters for yield and grain quality including ratio of grain length to grain width, gelatinization temperature and gel consistency, were significantly influenced by lodging and thus deteriorated. Regression analysis suggested that, lodging one day earlier at the grain-filling stage could cause 2.66% to 2.71% of yield loss, 1.8 to 2.6 percentage points decrease of seed-setting rate, 0.26 to 0.32 g reduction of lO00-grain weight, 0.097 to 0. 155 percentage point decline of milled rice rate, as well as 0.13 to 0.27 percentage point increase of chalky grain rate, and 0.021 to 0.024 percentage point rise of protein content, and subsequently lower the eating quality.

Changes in Activities of the Key Enzymes Related to Starch Synthesis in Rice Grains During Grain Filling and Their Relationships with the Filling Rate and Cooking Quality

With 10 rice cultivars (lines) as materials, the changes in activities of adenosine diphosphoglucose pyrophosphorylase(ADPGPase), starch synthase (SSase) and starch branching enzyme (Q-enzyme) in the grains during grain filling, and theirrelationships with the filling rate, gel consistency (GC), alkali spreading value (ASV) and amylose content (AC) werestudied. The results showed that changes in activities of ADPGPase, SSase and Q-enzyme exhibited a single peak duringgrain filling, and the time of the activity peaks for the former two enzymes was earlier than that of the maximum grain-fillingrate (Tmax), and the time reaching the peak for Q-enzyme was synchronous with Tmax. The activities at early grain fillingstage, and the mean and maximum activities of each enzyme during grain filling period were positively and significantly orvery significantly correlated with the mean and maximum grain filling rate and starch content (mg grain-1) in the grains.Activities of ADPGPase at all grain filling stages and those of Q-enzyme at the early and mid filling stages were notsignificantly correlated the cooking quality (GC, ASV and AC). SSase activities at the early filling stage were significantlyand negatively correlated with GC and ASV, and positively correlated with AC. Activities of SSase at mid and late grainfilling stages and Q-enzyme at the late filling stage were significantly and positively correlated with GC and ASV, andnegatively correlated with AC. Spraying zeatin or abscisic acid at early grain filling stage could obviously regulate theactivities of ADPGPase, SSase and Q-enzyme in the grains.

Combined effect of shading time and nitrogen level on grain filling and grain quality in japonica super rice

There is limited information about the combined effect of shading time and nitrogen （N） on grain filling and quality of rice. Therefore, two japonica super rice cultivars, Nanjing 44 and Ningjing 3, were used to study the effect of shading time and N level on the characteristics of rice panicle and grain filling as well as the corresponding yield and quality. At a low N level （150 kg N ha^-1, 150N）, grain yield decreased （by 21.07-26.07%） under the treatment of 20 days of shading before heading （BH） compared with the no shading （NS） treatment. These decreases occurred because of shortened panicle length, decreased number of primary and secondary branches, as well as the grain number and weight per panicle. At 150N, in the treatment of 20 days of shading after heading （AH）, grain yield also decreased （by 9.46-10.60%） due to the lower grain weight per panicle. The interaction of shading and N level had a significant effect on the number of primary and secondary branches. A high level of N （300 kg N ha^-1, 300N） could offset the negative effect of shading on the number of secondary branches and grain weight per panicle, and consequently increased the grain yield in both shading treatments. In superior grains, compared with 150N NS, the time to reach 99% of the grain weight （T99） was shortened by 1.6 to 1.7 days, and the grain weight was decreased by 4.18-5.91% in 150N BH. In 150N AH, the grain weight was 13.39-13.92% lower than that in 150N NS due to the slow mean and the maximum grain-filling rate （GRmean and GRmax）. In inferior grains, grain weight and GRmean had a tendency of 150N NS〉150N BH〉150N AH. Under shaded conditions, 300N decreased the grain weight due to lower GReen both in superior and inferior grains. Compared with 150N NS, the milling and appearance qualities as well as eating and cooking quality were all decreased in 150N BH and 150N AH. Shading with the high level of 300N improved the milling quality and decreased the number of chalky rice kernels, but the eating and cooking quality was reduced with increased chalky area and overall chalkiness. Therefore, in the case of short term shading, appropriate N fertilizer could be used to improve the yield and milling quality of rice, but limited application of N fertilizer is recommended to achieve good eating and cooking quality of rice.

Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

Effect of Temperature at Grain Filling Stage on Activities of Key Enzymes Related to Starch Synthesis and Grain Quality of Rice

Three japonica rice varieties with different cooking and eating quality were grown at high temperature in the greenhouse and natural field. Effects of temperature at the grain filling stage on these varieties were investigated in terms of the activities of key enzymes related to starch synthesis and cooking and eating quality of rice grain. The high temperature at the grain filling stage increased protein content, and decreased amylose content and taste meter value of rice; inferior grain quality varieties showed a greater magnitude of the increase or decrease than the superior ones. Reaction of rapid visco analyser profiles to the temperature varied with rice varieties. The activities of adenosine diphosphoglucose pyrophosphoryiase （AGPP）, soluble starch synthase （SSS） and starch branching enzyme （SBE） gradually increased to a peak value, and thereafter declined as grain filling progressed. Enzyme activities in different varieties differed in a same filling stage, and also in the time when the enzyme activity reached a maximum. AGPP and SSS were insensitive to the environmental temperature, but SBE was comparatively sensitive to the temperature, and its activity declined when temperature was too high or too low.

Strength evolution and deformation behaviour of cemented paste backfill at early ages： Effect of curing stress, filling strategy and drainage

In this study, a pressure cell apparatus is developed to investigate the early age evolution of the strength and deformation behaviour of cemented paste backfill(CPB) when subjected to various loading conditions under different curing scenarios. The different curing scenarios that are simulated include:(1)drained and undrained conditions,(2) different filling rates,(3) different filling sequences, and(4) different curing stresses. The findings show that drainage, curing stress, curing time and filling rate influence the mechanical and deformation behaviours of CPB materials. The coupled effects of consolidation, drainage and suction contribute to the strength development of drained CPB subjected to curing stress. On the other hand, particle rearrangement caused by the applied pressure and suction development due to self-desiccation plays a significant role in the strength gain of undrained CPB cured under stress.Furthermore, curing stress induces slightly faster rate of cement hydration, which can contribute to strength acquisition.

Relationship Between Variation in Activities of Key Enzymes Related to Starch Synthesis During Grain Filling Period and Quality of Eating and Cooking in Rice

Four japonica rice varieties with significant differences in quality of eating and cooking were used in the experiment. The varieties showed differences in amylose and amylopectin contents at different grain filling stages, which were attributed to the accumulative speed of starch at different grain filling stages. During grain filling period, the varieties had no difference in the time when the activities of ADPglocose pyrophosphorylase （AGPP） and soluble starch synthesis （SSS） reached a maximum, but had difference in the time when the activity of starch branching enzyme （SBE） reached a maximum, in which the inferior quality varieties were earlier than the high quality ones, and high quality varieties still kept high enzyme activities at the late stage of grain filling. The correlation and correlative degree between AGPP, SSS, SBE and amylose content, amylopectin content, taste meter value, and RVA properties varied with the different stages of grain filling. The correlation between SSS activity and taste meter value was not significant during the whole period of grain filling, but the activities of AGPP and SBE had significant or highly significant correlation with taste meter value. It was helpful for improving quality of eating and cooking of japonica rice to use the materials with low enzyme activity at the early stage of grain filling or high enzyme activity at the late stage as parents.

Mold Filling Analysis in Vacuum Infusion Molding Process Based on a High-Permeable Medium

The objective of this paper is to understand the flow mechanism through visualization experiments and discuss theinfluence of process parameters on mold filling process. A 2D leakage flow model is developed to simulate the moldingprocess, and the simulation results show good agreement with experiments.