Process design and control of greensand mold press casting using estimation of metal filling behavior

A novel technique for controlling the molten metal filling behavior in the casting production is developed. The molten metal often fountains from a narrow flow path to the wide path in the cavity, so that flow disturbance and air entrainment occur. We propose a filling process design approach comprising model predictive control method. The effectiveness of the process control design of pressing motion with the liquid pressure of filled molten metal and the steady flow without fountaining is confirmed by computational fluid dynamics analysis and laboratory experiment of iron metal casting.