Ijesrt: International Journal of Engineering Sciences & Research Technology
Ijesrt: International Journal of Engineering Sciences & Research Technology
ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
IJESRT
INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH
TECHNOLOGY
Simulation of Casting and Its Validation by Experiments
Mazhar Iqbal*, Sushil Patel, Ganesh Vidyarthee
Department of Foundry-Forge Technology, National Institute of Foundry & Forge Technology, Hatia,
Ranchi, India
mazhariq1@gmail.com
Abstract
Now days in Industries it is very important to save time and money in manufacturing product, because there
is lots of competition in industrial world. Main objective of this project is re-designed of component using Pro-cast
software and increasing the product life of the components. Many researchers reported that about 90% of the defects
in castings are due to wrong design of gating & risering system and only 10% due to manufacturing problems. to
optimize gating/riser systems based on CAD and simulation technology with the goal of improving casting quality.
Therefore in the thesis, an optimization framework is presented based on CAD and simulation technology. Given a
CAD model of part design and after converted to a casting model. After analyzing simulation results, the gating/riser
system design is optimized to improve casting quality. In this thesis, one journal bearing is used to verify the
effectiveness of the optimization method. Compared with the initial design. Casting simulation process can able to
solve these problems. The simulated results also compared with the experimental works..
Keywords: Casting, Sand casting.
in this thesis is to optimize riser systems based on
CAD and simulation technology with the goal of
improving casting quality such as reducing incomplete
filling area, decreasing large porosity and increasing
yield. Therefore in the thesis, a CAD and simulation
technology based optimization framework is
presented. Given a CAD model of part design and after
its being converted to casting model, the first objective
is to evaluate castability of the casting design. Then
risers are presented parametrically. After analyzing
simulation results, the original riser system design will
be optimized to improve casting quality.
Introduction
Casting is a manufacturing process for
making complex shapes of metal materials in mass
production. There are two main consecutive stages,
filling process and solidification process, in casting
production. In filling process gating system composed
of pouring cup, runner, sprue, sprue well and ingate, is
designed to guide liquid metal filling. Riser system is
used to compensate shrinkage caused by casting
solidification. How to improve the casting quality
becomes important. Casting quality is heavily
dependent on the success of riser system design, which
currently is conducted mainly relied on technicians
experience. Therefore there is a need for the
development of a computer-aided casting process
design tool with CAD, simulation, and optimization
functions to ensure the quality of casting. Casting
process simulation was initially developed at
universities starting from the early '70s, mainly in
Europe and in the U.S., and is regarded as the most
important innovation in casting technology over the
last 50 years. The objective of the research presented
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
journal bearing
Design of riser
According to the dimensions and wt. of component the riser design was done. Along with riser design, using different
formulas other dimensions of elements like sprue, sprue well, runner, ingate also calculated.
Calculation
Design of riser by Modulus method:
Volume of the casting = 5*106 mm3
Surface area of the casting = 2.78*105 mm3
Volume of the riser = *D3/4
Surface area of the riser = .D2 + *D2/4 = 1.25D2
Where D is the riser diameter.
Modulus of the casting = volume of the casting / surface area of the casting
= 5*106 / 2.78*105
= 17.98
According to the formula
Modulus of the riser = 1.2* Modulus of casting
= 1.2*8.953197097
= 21.58.......................................Eq. 1
Now,
Modulus of riser = (*D3/4) / (1.25D2)
D/5..........................................................Eq.2
Comparing eq.1 & 2
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
D = 107 mm
Pouring time- The time for complete filling of mould termed as pouring time.
Pouring time t = (2.4335 - 0.3953 log w)*w sec.........For steel casting [40]
Where,
W = mass of the casting, kg
t = (2.4335- 0.3953log34.073)*34.073
= 10.66 sec
Choke area = The main control area which meters the metal flow into mould cavity so that mould is completely filled
within the calculated pouring time. Normally choke area happens to be at the bottom of the sprue.
Choke area/ sprue bottom area A = W/dtc2gh
Where,
W = casting mass, kg
d = density of molten metal kg/mm3
H = effective height of metal head (sprue height) in mm
C = efficiency factor for gating system
t = pouring time (sec)
A = 34.073/ (7.85*10-6 *10.66*.9*2*9810*110)
= 308 mm2
d2/4 = 221
d = 19.8 mm
Sprue top area = 2*sprue bottom area
D2/4 = 2*308
D = 28mm
Ingate and runner dimension:
Gating ratios
It is expressed as the ratio of sprue area to the total runner area to the total ingate area.
Gating ratio = sprue area : runner area : ingate area
Gating ratio of material
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
Optimization
Out of various simulations considering casting yield and sound component best design of riser was selected.
Result of simulation runs
Run
Run1
Run2
Run3
Run4
Run5
Run6
Run7
Run8
Run9
Run10
Run11
Porosity
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Yes
Yes
No
Vol. Of
casting
(mm3) in
106
5
-
Vol.
casting
Gating
risering
(mm3)
106
6.25
6.17
6.09
6.41
6.84
6.75
7.35
7.14
6.49
6.57
6.94
Of
+
+
in
Mass of
casting +
gating+
risering
(Kg)
42.54
42
41.55
43.68
46.67
46
50.10
48.67
44.25
44.83
47.32
Casting
yield
(%)
80
81
82
78
73
74
68
70
77
76
72
Result: The casting yield of the component (journal bearing) of simulation Run11 is optimum result and calculated
as under.
Casting Yield
By the formula
Casting yield = (Vol. of the actual casting)/(Vol. Of the casting+ vol. Of gating &risering system)
=5*106/6.94*106
= .72
Casting Yield%
= 72
Experimental details: For the component journal bearing taking the following parameters same the nos. Of
simulations was carried out. The different simulation parameters are as given under
Step
No. of Nodes
No. of Solids (TETRA/HEXA/WEDGE)
No. of Enclosure Elements
No. of Materials
=40000
= 116407
= 600808
=0
=2
Material:
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
Fig. Voids
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
Mould preparation
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preheat of ladle
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
After solidification
Conclusion
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Casting
simulation
technology
has
sufficiently matured and has become an
essential
tool
for
casting
defect
troubleshooting and method optimization. It
enables quality assurance and high yield
without shop-floor trials, and considerably
reduces the lead-time for the first good
sample cast.
By analysing simulation results, the
optimized riser system is determined.
By comparing the simulation result of
optimized casting model with that of the
original model, it can be concluded that the
porosity volume decreased and the yield
increased
In shrinkage porosity diagram, it clearly
shown that all shrinkage are at the riser and
sprue and the component is shrinkage free
which implies a sound casting.
By using pro-cast simulation software the
casting yield is found to be 72%. Which is
greater than original one
By moving the trial and error process into the
virtual world and determine the cost of
different design and process options. By
minimizing real world trial and error (and
surprises) making castings right the first time.
From the above study it can be concluded that
the defect analysis done by simulation help a
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ISSN: 2277-9655
Scientific Journal Impact Factor: 3.449
(ISRA), Impact Factor: 1.852
4. Bawa, H S (2004). Manufacturing Processes
I. Tata McGraw-Hill. pp. 112. ISBN 978-007-058372-6.
5. Ammen, C. W. (1999). Metalcasting. McGrawHill Professional. pp. 159176. ISBN 978-007-134246-9.
6. Degarmo, Black & Kohser 2003, p. 311.
7. http://wwwold.me.gatech.edu/jonathan.colton/me4210/c
astdefect.pd
8. Ravi B, Metal Casting: Computer-Aided
Design and Analysis, Prentice-Hall, New
Delhi, India, 2005.
9. ASM Metals Hand book Vol.-15, casting page
63,64.
10. http://en.wikipedia.org/wiki/Riser_(casting)
11. P L Jain Principles of Foundry Technology
Tata McGraw Hill Publishing Company
Limited New Delhi Fourth Edition p 207.
12. Campbell, J., 2003. Castings. Elsevier
Butterworth-Heineman
References
1. http://en.wikipedia.org/wiki/Casting
2. R. Gregg Bruce, M.M. Tomovic, J.E. Neely,
R.R. Kibbe, Modern Materials and
Manufacturing Processes, 2nd ed., PrenticeHall, 1998.
3. Serope Kalpakjian, Steven R. Schmid,
Manufacturing Engineering and Technology,
Fifth Edition, Prentice Hall, NJ, 2006
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