Simulation of Casting and Its Validation by Experiments (original) (raw)
Related papers
Design and Optimization of Gating and Feeding System for Casting: A Review
In the global competitive environment there is a need for the casting units and foundries to develop the components in short lead time. Casting as a manufacturing process to make complex shapes of metal materials in mass production may experience many different defects such as gas porosity, pin holes, blow holes, shrinkages and incomplete filling. The Gating/riser system design play very important role for improving casting quality. Due to the lack of scientific procedures the designing process is normally carried on a trial-and-error basis. The main objective of this paper is to present the literature review based on recent trends in casting process, design and optimize gating and feeding system of casting,defects minimization by casting simulation, solidification analysis of casting, gaps in literature and introduction of various types simulation software with the goal of improving casting quality such as reducing gas porosity, pin holes, gas holes incomplete filling area and increasing yield. This reviews paper considers the idea about the design and optimization of gating and feeding system which is based on CAD and simulation technique.
Effective use of Casting simulation for improving Bearing Housing Casting's Yield
Casting defects can negatively impact the bottom line of foundry. A defect in a casting deteriorates casting surface quality and mechanical properties. It is responsible for loss of profitability, quality level and productivity of component. Hence it is preferably necessary to reduce it as much as possible by appropriate analysis. As far as the casting with thick sections are concerned, finding the Hot Spot is very important, asMost of the casting defects occur due to " Hot spot " which is the part of casting that gets solidified last. This paper presents case study carried out in local foundry over Bearing Housing to minimize casting rejection due to major defects like blow hole and shrinkage cavities. Study is focused on route cause analysis of Blow holes and shrinkage cavities defect which contribute heavypercentage of rejection.The objective of this research is to optimize gating system by using simulation software with proper location of Feedaids like Riser, vent holes , chills and insulating sleeves based on pictorial results based on CAD and simulation tools with the goal of improving casting quality and increasing casting yield
Analysis & Simulation of Casting to Eliminate Casting Defects
2016
ARTICLE INFO As the foundries are primary suppliers to the manufacturing industries like automobile, Pumps, transport, heavy equipment, machine tools, plant machinery, machines, households, aerospace, defence. Although lots of research has been carried out in foundry technology, yet achieving higher casting yield with the sound casting (defect free casting) is major challenge to the manufacturers. For obtaining high quality of casting which is a customer prime requirement manufacturers are making compromise with the casting yield. Which results into the increases production cost and decreases profit. In the research pump cover casting is analyzed which is associated with the various defects. Defective casting results due to improperly designed gating system and risers. For eliminating the defects the gating system components such as sprue , sprue well ,ingates and risers are redesigned using the feeding rules , gating design procedure, theoretical knowledge , practical consideration...
Optimized Design of Risering System for Casted Component by Using Web Based Online Simulation E-Tool
The highest levels of casting yield should be attainable under mass scale production conditions, where there is wide opportunity for early experiment at the risk of defective castings and where gross weight can be reduced by progressive use of proper feeder head dimensions and use of different feedaids. Virtual Casting Simulation may used to assure sound quality of castings and yield optimization without carrying and charging out shop floor trails, it also helps to analyze and optimize feedability of a casting during predesign phase. A well-designed runner and gating system is very important to produce sound castings by providing a homogenous mould filling pattern. Defects such as Shrinkage porosity, Cold shuts, Misrun, and Gas porosity leads to heavy rejection upto 50% also. In order to improve the quality of the castings produced, the gating system was changed from the pre existing flat gate to a modified fed gate. Major parameters of a feeding system include are feeder modulus, n...
Review of Optimization Aspects for Casting Processes
2015
In today’s global competitive environment there is a need for the casting set ups and foundries to develop the components in short lead time. Defect free castings with minimum production cost have become the need of this indispensable industry. Rejection of casting is caused due to defective components. These defects depend on various process parameters which need to be improved using various methods in optimization. The IT industry with the help of manufacturing industry have developed various software packages which simulate the casting process which help to identify the parameters affecting the quality of castings. The simulated results can be used to predict the defects, optimize the factors and take corrective steps to minimise these defects. This paper provides comprehensive literature review about optimization aspects of casting process and shows shear necessity of investigation of the process parameters and process optimization.
The Application of Simulation Technology in the Parameter Optimization of Casting Process
MATEC web of conferences, 2016
Since the casting process of large castings is complicated, the optimization of process parameters has a significant impact on product quality. In this paper, main technical parameters of male thread casting in screw expansion power machine were compared and analyzed with simulation analysis method and an applicable speed and temperature for male thread casting was obtained by mainly considering the entrapped air and the surface defect density. In general, the analysis methods provided herein, offers a viable way to optimize the quality of large machine components while casting. This can benefit the productivity and cost saving. This is an Open Access article distributed under the terms of the Creative Commons Attribution License 4.0, which permits distribution, and reproduction in any medium, provided the original work is properly cited.
Optimization of riser neck for aluminium casting by using simulation tool
2017
The Gating and riser system design play very important role for improving casting yield. These defects can be reduced by making suitable changes in feeding constraints, such as feeder location, size, shape etc. and also by making some changes in feeder neck dimension. By choosing the correct set of parameters we may lead to the desired quality and yield, but difficult to achieve it. This is the reason that a need has arisen for computer aided casting simulation tool coupled with solidification simulation to reduce the number of shop floor trials and obtain enhanced yield and high quality, in minimal possible time. In this paper an auto industry part model is considered to study the solidification behaviour of aluminium alloy A356 along with detection of hot spots in castings with the help of AutoCAST XI simulation software and the effect of neck height on casting yield is also being studied. Keywords— AutoCAST XI, casting simulation, gating and riser design, hotspots, shrinkage cavity
2021
The current trend in foundries is to achieve the production of high quality and competitive cast components. The innovation and optimization of current processes is a necessary element to achieve this goal. With the help of numerical simulations, it is possible to replace financially demanding and time-consuming experiments in real conditions with simulations that can reliably represent foundry process using computer technology. By a detailed analysis of the simulation results, we can predict various risks that could negatively affect the production process. This article monitors the influence of changes in the design of the gating system on the surface quality of a clutch wheel casting made of ductile iron, in the production of which two models of the gating system for casting were constructed in CAD software. Verification of gating systems was performed using the simulation software NovaFlow & Solid. The aim of the design change of the gating system is to reduce the amount of liqu...
Design Optimization Through Casting Simulation Software For Sand Casting
Porosity is the one of the defects most frequently encountered in ductile iron casting. Porosity formation cause costly scrap loss and limits the use of cast parts in critical high strength applications. The amount of porosity is closely related to sand casting processes parameter. A considerable reduction in porosity formation can be obtained using optimization technique in the sand casting process. Casting is a manufacturing process to make complex shapes of metal materials in mass production may experience many different defects such as gas porosity, pin holes, blow holes, shrinkages and incomplete filling. The Gating/riser system design play very important role for improving casting quality. Due to the lack of scientific procedures the designing process is normally carried on a trial-and-error basis. The main objective of this paper is to redesign the components using Auto-CAST X1 simulation software and increasing the product life. Many researchers reported that 90% of the defects in casting are obtained only because of wrong design of gating and feeding system and only 10% due to manufacturing problems. In this paper to study the solidification behavior of material, detection of hot spots, blow holes and removed such defects in the casting with the help of mentioned casting simulation software. The simulated results also compared with experimental results.
Casting is a manufacturing process to make complex shapes of metal materials; Q4 during mass production, we may experience many defects, such as gas porosity, pin holes, blow holes, shrinkages and incomplete filling that may occur in sand casting. Porosity is one of the defects most frequently encountered in ductile iron casting. Porosity impacts cost by scrap loss and limits the use of cast parts in critical high strength applications. The amount of porosity is closely related to the parameter of sand casting process. The gating/riser system design plays a very important role for improving casting quality. Many researchers reported that 90% of the defects in casting are obtained only because of improper design of gating and feeding system. The main objectives were to study the existing design of gating and feeding system, to optimize the gating and feeding system using Auto-CAST X1 casting simulation software, to prepare the sand mold and cast the part, to compare the simulated result and experimental results, to reduce rejection rate and to enable the company to again start the production.