Numerical Study of Impingement Location of Liquid Jet Poured from a Tilting Ladle with Lip Spout
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UCTION
THE cast-iron foundry industry produces cast parts for automotive, agriculture, transportation, energy, aerospace, manufacturing industry, etc., with 90 pct of manufactured products containing cast-iron parts. All foundry processes generate a certain level of rejected parts, which are irrecoverably lost, being closely related to the type of casting and processes used and the equipment available. As quality demands from endusers of castings increase, it is essential that cast-iron technology move forward, together with green manufacturing as a first step towards sustainability. Extensive work has been carried out by the foundry community to minimize casting defects such as porosity, slag, and clogging, but few literature reports consider casting metal using more versatile melt control technology. The flow control system in a tundish has a significant impact on the quality and level of rejection when pouring casts. If the metal does not flow in a consistent stream, casting defects may result from oxidation, air entrapment, and erosion of the pouring mold, among other causes. In the cast-iron industry, it is usual for molten metal to be transfered from a ladle with a lip-axis pour design.[1] This method is fast and reliable, but inaccurate unless a sophisticated control system is used.[2–4] In recent years, our group has been working on technologies that aim to transform the conventional R. CASTILLA, P. J. GAMEZ-MONTERO, G. RAUSH, and E. CODINA are with the LABSON, Department of Fluid Mechanics, Universitat Politecnica de Catalunya, 08222, Terrassa, Spain. Contact e-mail: [email protected] M. KHAMASHTA is with the LABSON, Department of Mechanical Engineering, Universitat Politecnica de Catalunya, 08222, Terrassa, Spain. Manuscript submitted July 26, 2016. Article published online February 7, 2017. 1390—VOLUME 48B, APRIL 2017
(batch-by-batch) foundry process into a flexible (moldby-mold) process. This requires that the ladle become a furnace as well, that the tundish be eliminated from the process, and that the molten metal be poured directly into the mold. Moreover, it is convenient for the pouring flow rate to be constant to obtain uniform refilling of the mold. Such a flexible mold-by-mold process is characterized by, firstly, combination of the melting, treatment, and pouring processes into a single cast-iron production cell. Also, this requires integration of an artificial-intelligence-based control system to monitor local structures, phases, and mechanical properties to guarantee high-quality casting in the foundry. Finally, a robot cell will be in charge of the metal finishing process. This also reduces the melt temperature and transport while improving validation of the cast pieces. In recent decades, extensive effort has been invested in development of CFD simulation methods for application in the casting industry, especially for multiphase flows.[5–7] In the particular case of simulations of pour tilt casting, Prakash et al.[8] used the smoothed particle hydrodynamics method to simulate the oxidation process duri
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