A transient, three-dimensional, multi-phase particle-in-cell approach is used to solve for the flow of polystyrene beads in complex three dimensional geometries which represent patterns used for lost-foam casting. The numerical method solves the gas conservation equations on an Eulerian grid and the motion of polystyrene beads is calculated in a Lagrangian frame of reference. The true particle size distribution is modeled, and the particle flow ranges from dilute to close-pack. Predicted fill behavior is compared to experimentally blown patterns using colored beads and to the measured transient filling of a pattern. The colored beads show a complex fill pattern which is calculated well by the numerical method. The transient calculation compares very well with measured video data, and the particle motion has unique particle behavior unlike a fluid. Because of uncertainties in boundary conditions in production lost-foam tooling, the sensitivity of lost-foam pattern filling to boundary conditions is examined.
- Manufacturing Engineering Division and Materials Handling Engineering Division
Process Modeling: Lost-Foam Pattern Filling
- Views Icon Views
- Share Icon Share
- Search Site
Blaser, PJ, Snider, DM, Williams, KA, Cook, AE, & Hoover, M. "Process Modeling: Lost-Foam Pattern Filling." Proceedings of the ASME 2004 International Mechanical Engineering Congress and Exposition. Manufacturing Engineering and Materials Handling Engineering. Anaheim, California, USA. November 13–19, 2004. pp. 261-267. ASME. https://doi.org/10.1115/IMECE2004-60483
Download citation file: