Design, Construction and Simulation of Filling a Green Sand Mould for Casting White Aluminum Parts

Abstract

This work shows a comparative analysis of the results obtained through the casting trial-error technique and the use of CFD (computational fluid dynamics) simulation software in the design and optimization stages of molds in the casting industry. Its objective is to show small and medium industry entrepreneurs nationwide that the use of this technology is beneficial in order to reduce operating costs associated with testing for the manufacture of models and molds of parts and the optimization of the same in their foundries. The project focuses on the use of ANSYS Fluent software, through which it is intended to perform simulations of mold filling and solidification of parts in order to anticipate failures that could occur before resorting to practical tests, which represents a high cost, reducing the percentage of profits. For the analysis, the mold dimensions and variables such as speeds, flow rates, flow and cooling times have been calculated for later use in the software configuration. Once the simulations have been carried out and in order to validate the results obtained, they have been compared with the practical tests carried out, in order to have a comparison of the same data that had good impressions. Through this research work, it is demonstrated that there is the possibility of predicting defects in castings in advance, using computer simulation tools, thus achieving the minimization of errors and improving productivity.
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