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Modeling of an aerospace sand casting process

by Ziolkowski, Joseph Edmund.

Abstract (Summary)
Theoretical issues relating to the aerospace sand casting simulation are laid out, identifying parameters used in the model. A sensitivity analysis is performed to examine the mold-metal heat transfer coefficient, mold thermal conductivity, wall friction factor, pouring basin pour temperature, and pouring basin head pressure through doing coupled flow simulations on thin-walled castings using the commercial casting simulation software, MAGMASOFT®. A verification exercise is done to match simulation with reality with the knowledge that mold-metal heat transfer coefficient and mold thermal conductivity are the most influential parameters of the five. Validation on a real production casting is performed using the tuned parameters from the verification exercise. ii
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Advisor:

School:Worcester Polytechnic Institute

School Location:USA - Massachusetts

Source Type:Master's Thesis

Keywords:sand castings aluminum

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