Virtual analysis of influence of a filter on mould filling

Abstract

Ceramic filters are used to avoid slag and impurities in foundry applications. When not properly applied, the presence of these filters may have a significant influence on mould filling. 3-D casting simulation has been applied to study the effects of the use of a ceramic filter on the metal flow in a gating system. Instead of using a pressure drop model to represent the behaviour of a fluid metal flow passing through a filter, a real exact filter geometry, which is created by a high resolution CT-scan and a non-destructive imaging technique, in the gating system is applied in the simulation. In this research, nodular cast iron is poured into a block casting. A depressurized gating system is used. After a choke, a filter with different orientations is placed in the system. Mould filling coupled with temperature is simulated. Geometries using different orientations of the filter, and without the filter have been researched. The simulated results show that the filter has no influence on the pouring time of the casting if the choke section is small enough compared to the effective section of the filter. Although the filter has no significant influence on the flow patterns in the block casting itself, the flow patterns in the filter zone are different. When the liquid metal passes a horizontal filter, it will be broken into many small streams and show a shower effect. After the part under the filter is full, the shower effect disappears. When the filter is located at the vertical position, due to the gravity, the shower effect is less. If no filter presents on the system, the liquid metal passes through the filter zone with a high speed and causes surface turbulence