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Further evaluating iron filter print designs

 

 

Properly filtering iron castings involves utilizing the most optimally engineered filter print and gating system designs to ensure delivery of the cleanest and least turbulent metal to the mold cavity. In 2017, Tony Midea cowrote a Foundry Practice paper that documented qualitative analyses of filter print designs entitled “Evaluating Iron Filter Print Designs – 30 Years Later”1. That paper utilized the most advanced fluid flow technology to assess filter print designs fluid flow characteristics, and to recommend best practice application techniques and methodology to the iron foundry industry.

A follow-on study was undertaken to couple quantitative analyses with qualitative analyses to ensure that the best filter print designs were being recommended. Results from the quantitative analyses shown in this paper support the recommendations from 2017 and provide further insight on best practice filter print designs.

INTRODUCTION

This work focuses on analysis and evaluation of several filter print design concepts2-10 using casting process simulation software employing sophisticated, first principle fluid flow analysis models. The goal is to investigate problems experienced in foundries and maximize the benefits of filtration to deliver the best possible quality molten metal to the mold cavity, thereby producing high quality castings.

The first section of this paper will provide a summary review of the work documented in the 2017 paper referenced above. This includes the qualitative analyses that involved evaluating fluid flow characteristics within the filtration system to determine best practice.

The second section of this paper will document the methodology used to define the quantitative analyses and provide a detailed examination of the results from the quantitative analyses. The quantitative and qualitative analyses are combined to recommend best practice filter print designs.