Numerical modeling and simulation of mold filling and solidification process of BS100 Grade A6 alloy in sand casting of excavator bucket coupling parts

Volume 10, Issue 1, February 2025     |     PP. 25-35      |     PDF (350 K)    |     Pub. Date: July 1, 2025
DOI: 10.54647/materials430289    12 Downloads     469 Views  

Author(s)

Pham Quang, School of Materials Science and Engineering, Hanoi University of Science and Technology (HUST), Hanoi, Viet Nam

Abstract
Carbon steel bucket couplings are widely used in the construction and mining industries due to their quality and versatility. These couplings are manufactured using sand casting techniques to meet international standards. This casting technique has significant shrinkage defects during solidification and needs to be improved. In this study, JSCast simulation software was used to analyze the mold filling and solidification process of BS100 Grade A6 alloy during sand casting of excavator bucket couplings. The simulation provides important insights into the thermal and flow dynamics, allowing prediction and prevention of potential casting defects. The mold filling simulation demonstrated a steady and efficient flow of molten metal into the mold cavity, achieving full filling within 16.12 seconds. The temperature distribution throughout the filling process remained almost uniform, with minor cooling observed in the thinner and peripheral regions. There were no major flow defects such as airlocks, freeze-ups, or misruns, indicating that the runner system was well designed to promote smooth and complete filling. Solidification simulations showed a solidification pattern that progressed inward from the mold wall toward the core. The thinner sections solidified earlier, while the risers held the molten metal for a longer time—up to 676.17 seconds—allowing for effective shrinkage zones. The delayed solidification of the shrinkage beans relative to the casting was confirmed by the solidification fraction curve, confirming their role in reducing the risk of internal shrinkage and porosity.

Keywords
Numerical modeling, Jscast, sand casting, mold filling, solidification, excavator bucket coupling, BS100 Grade A6.

Cite this paper
Pham Quang, Numerical modeling and simulation of mold filling and solidification process of BS100 Grade A6 alloy in sand casting of excavator bucket coupling parts , SCIREA Journal of Materials. Volume 10, Issue 1, February 2025 | PP. 25-35. 10.54647/materials430289

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