Digital twin of functional gating system in 3D printed molds for sand casting using a neural network
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Digital twin of functional gating system in 3D printed molds for sand casting using a neural network Ahmed Ktari1
· Mohamed El Mansori1,2
Received: 17 December 2019 / Accepted: 16 October 2020 © Springer Science+Business Media, LLC, part of Springer Nature 2020
Abstract The filling stage is a critical phenomenon in sand casting for making reliable castings. Latest research has demonstrated that for most liquid engineering alloys, the critical meniscus velocity of the melt at the ingate is in the range of 0.4–0.6 m s−1 . The work described in this research paper is to use neural network (NN) technology to propose digital twin approach for gating system design that allow to understand and model its performances faster and more reliable than traditional methods. This approach was applied in the case of sand casting of liquid aluminum alloy (EN AC-44200). The approach is based first on a digital representation of filling process to perform the melt flow simulations using a combination of the gating system design parameters, selected as a training cases from Taguchi orthogonal array (OA). The second step of the approach is the data capture of functional gating design system to train up the feed-forward back-propagation NN model. The validation of the well-trained NN model is assessed by interrogating predicted ingate velocity to it and making reliable predictions with high accuracy. The claim is that such digital twin approach is an effective solution to recognize the functional design parameters from the entire filling systems used during casting process. Keywords Digital twin · Sand casting · Gating system design · FEM simulation · Neural Network
Introduction Sand casting is an economical metal forming process that has been employed, since antiquity, to manufacture metal parts with a wide range of sizes and complexity. However, to have a good quality castings, several rules should be respected in the mold designs in particular the gating system since it permits to control the melt flow in the cavity. The transition from laminar to turbulent flow during the mold filling can lead to drastic effects on the quality of castings (Campbell 2015). The filling process is typically comprised of free surface flow of the metal front inside the mold cavity. The exposure of liquid metals to air and moisture during free surface flows leads to the formation of surface oxide films (Gopalan and Prabhu 2011). Folding of free dry oxide surfaces result in
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Ahmed Ktari [email protected]
1
MSMP-EA7350, Arts et Métiers ParisTech, 2 Cours des Arts et Métiers, 13617 Aix-En-Provence, France
2
Department of Mechanical Engineering, Texas A&M University, College Station, TX 77840, USA
harmful double oxide films named bifilms (Campbell 2016; Raiszadeh and Griffiths 2006). Because these bifilms are necessarily folded on their dry sides during their creation, they act as cracks and initiate failure (Cao and Campbell 2003). The rate of bifilm formation increases with increase in turbulence as the oxide layers continuously stretch, ruptu
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