24 Techno PDF
24 Techno PDF
24 Techno PDF
Abstract—The development of computer aided design methods (trial & error) [1]. The current casting simulation
(CAE) technology, especially casting simulation software software has been widely accepted as an important tool in
(Magmasoft v5), can be utilized maximally as a tool to the design and development process of casting products
verify the design of castings that have been made to be that can improve casting yield and casting quality [2] [3].
able to meet the elements of QCD (quality, cost, delivery) Increased of casting yield can reduce cost of material, so
and compete in the market. This study aims to obtain an it will be savings cost that can make the product of the
optimal ESV housing casting design by reviewing and cast can compete in the market [4].
modifying the casting design in terms of both quality and Casting yield is the weight ratio of the cast product to the
economics. The process of design optimization with total weight of the casting (the weight of the cast product
casting simulation is an important step in the design and added with the total weight of the gating system).
development of casting products to improve casting yield Increase in casting value reflects the efficiency in the
and casting quality. The optimal design of castings is casting process which results in reduced material use and
obtained by improving the design through pouring system reduced production costs. The riser / feeder is the heaviest
using bottom pouring and optimizing the riser design. The component of the guttering channel (gating system)
results of this study obtained Design # 2 as a design which serves to supply additional metal liquid into the
choice of pouring system because it can improve the mold during shrinkage in the clotting process.
quality of casting products. Design # 2 optimized again Depreciation is affected by the effect of contraction that
into Design # 4 as the optimum design and able to occurs during freezing, either at [5]:
increase the yield casting by 5.11% from the previous 1. Liquid contraction (pouring temperature to
design (Design # 2). The result of techno economic liquids temperature)
analysis shows that by allocating 4% budget for design 2. Solidifying contraction (liquids to solids
cost can contribute to decrease of production cost of temperature)
foundry ESV housing up to 54,95%. 3. .Solid contraction (solids temperature to room
Keywords— Design optimization, Casting simulation, temperature)
Yield casting, Techno-economic. So in designing of gating system should consider the
existence of shrinkage factor (shrinkage allowance). In
I. INTRODUCTION Table 1 Shrinkage Allowance values can be shown as the
The development of computer aided design (CAE) amount of Shrinkage Allowance value on several main
technology, rapidly growing and becoming an integral material types.
part of industry development activities. One industry that
uses CAE applications is the casting industry. Table.1: Shrinkage Allowance [5]
Economically, the use of casting simulation is important Shrinkage Allowance
Material / Metal
because some advantages include: improve product ( % / [mm/mt] )
quality, because casting simulation can reduce the defect Cast iron 0.78 – 1.3 / [ 10 ]
of casting product, increase yield, so it can reduce feeder Aluminum alloys 1.3 / [ 15 ]
volume and gating channels per casting, modification to Bronze 1.0 – 1.6 / [ 16 ]
design can rapidly done, thereby reducing casting directly Steel 2.6 / [ 21 ]
by trial & error. This computational method of product
development is very advantageous than conventional
Fig.2. Potential areas to increase Yield Casting In this study there are four designs to be analyzed, as
shown in Figure 3 3D Gating System Design. Design # 1
Step of this research is: was an initial design that had been cast without preceded
a. Design optimization, design and simulation casting using Magmasoft simulation analysis and failed. Then the
for: analysis and comparison between non-destructive test
Design #1 :Result of first casting (rejected) results - Ultrasonic Test (NDT-UT) of castings product
Design #2:alternative first improvement design with Magmasoft simulation results, as shown in Figure 4
Design #3:alternative first improvement design Comparison of NDT-UT vs. Magmasoft.
Design #4:optimization of repair design
ACKNOWLEDGEMENTS
Acknowledgments to Director of Center for Technology
for Machinery Industry and PT. Nusantara Turbine
Propultion with PT. Copal Utama Indomelting who have
provided facilities for this research.
REFERENCE
[1] Gaumann, M. (2002). Investment Casting Simulation
Calcom, USA
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