Analysis & Simulation of Casting to Eliminate Casting Defects (original) (raw)
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IJERT-Identification of Casting Defects by Computer Simulation -A Review
International Journal of Engineering Research and Technology (IJERT), 2013
https://www.ijert.org/identification-of-casting-defects-by-computer-simulation-a-review https://www.ijert.org/research/identification-of-casting-defects-by-computer-simulation-a-review-IJERTV2IS80436.pdf Most common defect in steel castings is porosity, hotspot, blowholes.As a consequence the porosity formation is very closely studied phenomenon. The investigation described in this paper will examined the porosity formation in the casting component of Housing. In the current environment many casters still use the trial and error approach for process development. The capability to produce sound casting component of high quality of the same time reducing product costs & development times is the most highly challenge for the foundry today. Computer aided modeling plays an important role for the foundry industry for the past several years. Not only with the new design components but also in the redesign of existing products.Simulation gives the observed porosity and it will give the possibility to reduce porosity by changing appropriate gating system, riser design & modification.
2015
Computer simulation of casting process has emerged as a powerful tool for achieving quality assurance without time consuming trials. Software packages for simulating the solidification of molten metal in the mould enable predicting the location of shrinkage defects and optimizing the design of feeders to improve the yield; more advanced packages perform coupled simulation of mould filling and casting solidification. Simulation is the process of imitating a real phenomenon using a set of mathematical equations implemented in a computer program. In Casting simulation the mould filling and solidification analysis is done by using an algorithm or program based on finite volume method, to identify the hot spots and hence defects like shrinkage, hot tears, cracks, etc. [4]. In casting processes, there are various parameters which works at different levels may influence the casting defects. For each type of defect, several causes have been listed under differing categories such as design, ...
Minimization of the Casting Defects Using Taguchi's Method
This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting, parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on controlling the casting defects in foundry shop which comes in various check valves-PN 10 and these causes may results the reduction of quality of casting. Here we have studied minimize the casting defects using Taguchi's method through change in various parameters like as pouring temperature, green strength, mould hardness and permeability. These experiments were conducted based on standard acceptable and foundry men experience in this casting organization for casting check valves-PN 10 of various sizes & types Significant changes are taken during controlling the parameters. First we collected the data as casting defects from AV VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are four parameters responsible for these casting defects. 1. Pouring Temperature (o C) 2. Sand Particle Size (AFS) 3.Mould Hardness Number 4. Permeability Number First we define the range of these parameters and then we perform the casting process at different trial and find that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchi's method and use of MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in casting defects.