The influence of magnetic fields on the mechanical behaviour of granular materials used for foundry moulding: Numerical and experimental analysis

The comparative mechanical behavior of mold with magnetic molding using a cohesive granular material and lost foam process was compared. Finite element analysis calculates magnetic field and distribution of magnetic cohesion in steel shot moulds to determine optimum magnetizing equipment parameters. Internal friction measurements of steel shot and sand helps to compare the flowabilty of materials or their capacity to fill pattern cavity when filling the flash with steel shot. The magnetic cohesion of steel shots depends on its magnetization and its compaction ratio, greater internal cohesion leads to better dimensional tolerances and lower risks of steel shot mold collapse. The understanding of mechanical behavior of molds in two innovative foundry processes, lost foam and magnetic molding, helps to control parameters and casting quality. With magnetic molding, internal cohesion of steel shot molds can be determined according to the main process parameters and casting quality.