Data-driven casting defect prediction model for sand casting based on random forest classification algorithm

The complex sand-casting process combined with the interactions between process parameters makes it difficult to control the casting quality,resulting in a high scrap rate.A strategy based on a data-driven model was proposed to reduce casting defects and improve production efficiency,which includes the random forest(RF)classification model,the feature importance analysis,and the process parameters optimization with Monte Carlo simulation.The collected data includes four types of defects and corresponding process parameters were used to construct the RF model.Classification results show a recall rate above 90% for all categories.The Gini Index was used to assess the importance of the process parameters in the formation of various defects in the RF model.Finally,the classification model was applied to different production conditions for quality prediction.In the case of process parameters optimization for gas porosity defects,this model serves as an experimental process in the Monte Carlo method to estimate a better temperature distribution.The prediction model,when applied to the factory,greatly improved the efficiency of defect detection.Results show that the scrap rate decreased from 10.16% to 6.68%.

Microscopic sand production simulation and visual sanding pattern description in weakly consolidated sandstone reservoirs

To visually describe the sanding pattern,this study constructs a new particle-scale microstructure model of weakly consolidated formation,and develop the corresponding methodology to simulate the sanding process and predict sand cavity shape.The microstructure model is a particle-objective model,which focuses on the random sedimentation of every sand grain.In the microstructure,every particle has its own size,sphericity and inclination angle.It is used to simulate the actual structure of cemented granular materials,which considers the heterogeneity and randomness of reservoir properties,provides the initial status for subsequent sanding simulation.With the particle detachment criteria,the microscopic simulation of sanding can be visually implemented to investigate the pattern and cavity shapes caused by sand production.The results indicate that sanding always starts initially from the borehole border,and then extends along the weakly consolidated plane,showing obvious characteristic of randomness.Three typical microscopic sanding patterns,concerning pore liquefaction,pseudo wormhole and continuous collapse,are proposed to illustrate the sanding mechanism in weakly consolidated reservoirs.The nonuniformity of sanding performance depends on the heterogeneous distribution of reservoir properties,such as rock strength and particle size.Finally,the three sanding patterns are verified by visually experimental work.The proposed integrated methodology is capable of predicting and describing the sanding cavity shape of an oil well after long-term sanding production,and providing the focus objective of future sand control measure.

Influence of core sand properties on flow dynamics of core shooting process based on experiment and multiphase simulation

The influence of core sand properties on flow dynamics was investigated synchronously with various core sands, transparent core-box and high-speed camera. To confirm whether the core shooting process has significant turbulence, the flow pattern of sand particles in the shooting head and core box was reproduced with colored core sands. By incorporating the kinetic theory of granular flow(KTGF), kinetic-frictional constitutive correlation and turbulence model, a two-fluid model(TFM) was established to study the flow dynamics of the core shooting process. Two-fluid model(TFM) simulations were then performed and a areasonable agreement was achieved between the simulation and experimental results. Based on the experimental and simulation results, the effects of turbulence, sand density, sand diameter and binder ratio were analyzed in terms of filling process, sand volume fraction(αs) and sand velocity(Vs).

Simulation Experimental Study on Hydrodynamics Process of Erosion and Sediment by Runoff in Grassland

[Objective]The aim was to study the simulation test of hydrodynamics process of erosion.[Method]Through the runoff scouring experiment,the property of soil erosion in Damaoqi grassland in Inner Mongolia was studied.The process and mechanism of soil erosion were studied.[Result]The results of runoff scouring experiment on inner Damaoqi steppe showed that the mean flow velocity of change slope increased with the discharge of flow and slope gradient.The mean silt content rate,the mean sediment transport rate and the mean sheer stress all increased when the discharge of flow increased,which changed in parabolic form with the increase of slope gradient and the critical gradient is 25°.The relationship between the mean sediment transport rate and the mean sheer stress was linear.[Conclusion]The study provided theoretic basis for the report of soil erosion in grassland in China.

Migration process of ammonium ion in saturated silty sand and sandy loam

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A new low-cost method of reclaiming mixed foundry waste sand based on wet-thermal composite reclamation

A lot of mixed clay-resin waste sand from large-scale iron foundries is discharged every day; so mixed waste sand reclamation in low cost and high quality has a great realistic significance. In the study to investigate the possibility of reusing two types of waste foundry sands, resin bonded sand and clay bonded sand which came from a Chinese casting factory, a new low-cost reclamation method of the mixed foundry waste sand based on the wet-thermal composite reclamation was proposed. The waste resin bonded sand was first reclaimed by a thermal method and the waste clay bonded sand was reclaimed by a wet method. Then, hot thermal reclaimed sand and the dehydrated wet reclaimed sand were mixed in certain proportions so that the hot thermal reclaimed sand dried the wet reclaimed sand leaving some water. The thermal reclamation efficiency of the waste resin bonded sand was researched at different heat levels. The optimized wet reclamation process of the waste clay bonded sand was achieved by investigating the effects of wet reclamation times, sand-water ratio and pH value on the reclaimed sand characteristics. The composite reclamation cost also was calculated. The research results showed that the properties of the mixed reclaimed sand can satisfy the application requirements of foundries; in which the temperature of the thermal reclamation waste resin bonded sand needs to be about 800 oC, the number of cycles of wet reclamation waste clay bonded sand should reach four to five, the optimal sand-water ratio of wet reclamation is around 1:1.5, and the pH value should be adjusted by adding acid. The mass ratio of hot thermal reclaimed sand to dehydrated wet reclaimed sand is about 1:2.5, and the composite reclaimed sand cost is around 100 yuan RMB per ton.

Standard method design considerations for semi-quantification of total naphthenic acids in oil sands process affected water by mass spectrometry： A review

Naphthenic acids are a complex class of thousands of naturally occurring aliphatic and alicyclic carboxylic acids found in oil sands bitumen and in the wastewater generated from bitumen processing. Dozens of analytical methods have been developed for the semiquantification of total naphthenic acids in water samples. However, different methods can give different results, prompting investigation into the comparability of the many methods. A review of important methodological features for analyzing total naphthenic acids is presented and informs the design of future standard methods for the semi- quantification of total naphthenic acids using mass spectrometry. The design considerations presented are a synthesis of discussions from an Environment and Climate Change Canada （ECCC） led taskforce of 10 laboratory experts from government, industry and academia during April 2016 and subsequent discussions between University of British Columbia and ECCC representatives. Matters considered are： extraction method, solvent, pH, and temperature; analysis instrumentation and resolution; choice of calibration standards; use of surrogate and internal standards; and use of online or offline separation prior to analysis. The design considerations are amenable to both time-of-flight and Orbitrap mass spectrometers.