Advancing sustainable casting through cryogenic gradient forming of frozen sand molds:Design,error control,and experimental validation  

作　　者：Jianpei Shi Zhongde Shan Haoqin Yang Shijie Dong Qinjiang Liu 

机构地区：[1]College of Mechanical and Electrical Engineering,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China [2]State Key Laboratory of Mechanics and Control for Aerospace Structures,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China [3]College of Material Science and Technology,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China [4]Department of Mechanical Engineering,Tsinghua University,Beijing 100084,China

出　　处：《Journal of Materials Science & Technology》2024年第36期211-226,共16页材料科学技术(英文版)

基　　金：supported by the National Key R&D Program of China(grant No.2021YFB3401200);the Jiangsu Provincial Basic Research Program(Natural Science Foundation)Youth Fund(grant No.BK20230885);the Special Technical Project for Equipment Pre-research(grantNo.30104040302).

摘　　要：Owing to its exceptional casting performance,substantial utilization of recycled sand,and environmen-tally sustainable characteristics,frozen sand mold casting technology has found extensive application across diverse sectors,including aerospace,power machinery,and the automotive industry.The focus of the present study was on the development of frozen sand mold formulations tailored for efficient machin-ing,guided by the performance and cutting fracture mechanism of frozen sand molds.A regional tem-perature control device was developed for the purpose of conducting cryogenic cutting experiments on frozen sand molds with varying geometrical characteristics and molding materials.The impact of milling process parameters on the dimension accuracy of both sand molds and castings,as well as castings’surface roughness,were systematically investigated by a whole-process error flow control method.The findings indicate that precise and efficient processing of complicated sand molds was achievable by using sand particles with sizes ranging from 106 to 212μm,and water content between 4 and 5 wt.%,freezing temperature below-25℃,and cutting temperature within the range of-5 to 0℃.Through the frozen-casting of representative components,it was validated that the machining error of the frozen sand mold was within±0.25 mm.Additionally,the dimensional accuracy of the flywheel shell casting conformed to the CT8 specifications.This study provides theoretical guidance for the selection of frozen-casting sand formulations and close-loop control of process size chains for complex metal parts,as well as an overall solution for the realization of sustainable development of green casting.

关 键 词：Frozen sand mold Cryogenic machining Dimensional accuracy Surface roughness Green casting 

分 类 号：TG2[金属学及工艺—铸造]