Lost Foam Simulation Helps Reduce Lost Foam Defects.
In the last year, Mercury Marine (Brunswick Corp.), Fond du Lac, Wisconsin Fond du Lac is a city in Fond du Lac County, Wisconsin, United States. The name is French for Bottom of the Lake (other translations have included Foot of the Lake  or Farthest End of the Lake  , has made dramatic strides in its ability to understand the lost foam casting process using computational fluid dynamics Computational fluid dynamics
The numerical approximation to the solution of mathematical models of fluid flow and heat transfer. Computational fluid dynamics is one of the tools (in addition to experimental and theoretical methods) available to solve (CFD CFD - Computational Fluid Dynamics ) software that allows engineers to model metal flow in the mold on the computer screen. CFD involves the solution of the governing equations for fluid flow and heat transfer at hundreds of thousands of discrete points on a computational grid in the flow domain. When properly validated, an analysis allows engineers to look inside the mold and determine the exact position of the flow front at any point in time, as well as the temperature and pressure of the metal at any point in the mold. This is far more information than can be obtained from plant trials and usually allows engineers to understand where problems might arise. The geometry of the model representing the mold can be changed quickly on the computer and re-analyzed to determine the effect of the change.
Mercury Marine first utilized this software several years ago when it approached Flow Simulation Services, Albuquerque, New Mexico “Albuquerque” redirects here. For other uses, see Albuquerque (disambiguation).
Albuquerque (pronounced [ˈæl.bə.kɚ.kiː], Spanish: [al.βu. , because it was having difficulty with folds in an engine block. The foundry was hoping to simulate the casting's metal filling and solidification processes as the first step to eliminating defects.
Numerical modeling of the lost foam process is a challenging task since fluid flow is strongly coupled to the heat transfer between metal and foam. To help address these problems, the service provider used Flow-3D software from Flow Science, Inc., Los Alamos, New Mexico Los Alamos (Spanish: Los Álamos, meaning "The Cottonwoods") is an unincorporated townsite in Los Alamos County, New Mexico. The population of the townsite alone was 11,909 at the 2000 census. The townsite or "the hill" is one part of town while White Rock is also part of the town. , which has a model designed to accurately simulate lost foam casting. Mercury Marine engineers provided the geometry for the 3.0-liter engine block and the metal feed system, including sprue sprue, chronic disorder of the small intestine caused by impaired absorption of fat and other nutrients. Two forms of the disease exist. Tropical sprue occurs in central and northern South America, Asia, Africa, and other specific locations. , runners and gate attachments, in the form of surface models in .STL (STereoLithography) A 3D printing file format created by 3D Systems for its stereolithography system. Also supported by many numerical control, rapid prototyping and rapid manufacturing machines, STL provides the surface geometry of the item in triangles. formatted files. Mercury Marine also provided thermophysical information on the properties of the foam pattern, Flow Simulation Services created a model with 900,000 cells that included the pattern and the mold.
The model took 4 days to run and the results predicted the location of the folds and whether they were sufficient to cause a defect. The results accurately predicted the defects that have been periodically occurring in the real-world casting process at Mercury Marine.