The author-proposed skeletal sand mold, which mainly includes a shell, air cavities and a truss support structure, has been experimentally proven to be very useful in controlling the cooling of casting at local areas and at different periods of the casting process. The modeling and simulation of the casting process using a skeletal sand mold were systemically analyzed. Complicated casting/mold and mold/air boundaries, and the thermal and mechanical behavior of the skeletal sand mold during the casting process were highlighted. A numerical simulation of the casting process of a stress frame specimen using a skeletal sand mold was performed. The temperature, stress and displacement fields of the casting and skeletal sand mold were obtained and compared with those using a traditional sand mold. The simulated results were validated with experiments. Using the skeletal sand mold, the cooling rate of the casting can be greatly improved due to the significant heat release from mold surface to environment. The residual stress and deformation of the casting can be reduced because of the decreased stiffness of this kind of mold. Although the skeletal sand mold is susceptible to cracking, it can be avoided by filleting in the conjunctions and increasing the shell thickness.

In sand casting, gas porosity is a common defect that can result in decreased strength, leakage, rough surfaces, or other problems. Although the forming mechanism is very complicated, gas release from sand cores is often a significant contributor to the formation of gas porosity defects. Therefore, studying the gas release behavior of sand cores is crucial to solving this problem. Current research on the gas release behavior of sand cores mainly focuses on parameters such as gas permeability and gas generation properties, through experimental measurement and numerical simulation methods. However, accurately reflecting the gas generation situation in the actual casting process is difficult, and there are certain limitations. To achieve the actual casting condition, a sand core was designed and enclosed inside a casting. The core print was extended to the sand mold surface, with two types of core prints: hollow and dense. Pressure and airflow speed sensors were installed on the exposed surface of the core print to investigate the burn-off of the binder of the 3D-printed furan resin quartz sand cores. The experimental results showed that the gas generation rate was high in the initial stage of the burn-off process. The gas pressure quickly reached its peak in the initial stage and then decreased rapidly. The exhaust speed of the dense type of core print was 1 m/s, lasting for 500 s. The pressure peak of the hollow-type sand core was 1.09 kPa, and the exhaust speed peak was 1.89 m/s. The binder can be sufficiently burned off for the location surrounding the casting and the crack-affected area, so the burnt sand appears white, while the burnt core appears black due to insufficient burning of the binder because of isolation from the air. The gas generated by the burnt resin sand in contact with air was 30.7% less than that generated by the burnt resin sand insulated from the air.

A multishell mold structure and water-immersion cooling method (MSMWI) is proposed for the directional solidification of castings. A four-layer-shell sand mold was designed for a bar with diameter of 40 mm. As the aluminum melt was poured, the multishell mold was gradually immersed in water, and the water level drove the advancement of the solidification front from bottom to top. The multishell mold was helpful for the heat insulation of its upper part, and its bottom was chilled by the water. Therefore, directional solidification of the bar was vertically realized. The water-cooled solidification process of the bar was 5.8 times faster than that by air natural cooling (MSMNC), and the temperature gradient was increased by 78 times. The secondary dendrite arm spacing (SDAS) and eutectic silicon were significantly refined. Its tensile strength, elongation, and hardness were increased by 56%, 185%, and 62.6%, respectively.

Aiming at the problems of low stability and limited application conditions in traditional augmented reality, Unity 3D software is applied to realize augmented reality by combining with Vuforia SDK and EasyAR SDK (Software Development Kit). The developed results can be used on mobile terminal and augmented reality glasses-Hololens. At the same time, the 3D registration technique is studied for the augmented reality. Moreover, the principle and process to realize augmented reality in Unity3D and SDK are given. Finally, with the common image markers, the stability of the two SDKs was tested and analyzed with the angular variation experiment. Compared with the traditional system, the model stability is improved. (c) 2019 The Authors. Published by Atlantis Press SARL. This is an open access article distributed under the CC BY-NC 4.0 license (http://creativecommons.org/licenses/by-nc/4.0/).

Virtual Reality (VR) technology is widely used in digital cities, industrial simulation, training, etc. where the environment modeling is a necessary component. Comparing with the difficulty to build the three dimension (3D) environment with the conventional methods, the Structure from Motion (SFM) method is proposed in this paper. The modeling accuracy is studied by comparing with the real dimensions. The results show the SFM method can give a high precision reconstructed 3D model in a short time.