The Paper Presentation which won the award for 'Best Paper' at 5th International Conference on Industrial Engineering 2019, S.V.N.I.T., Surat, India. Presentation elaborates research carried out for the same paper published in the conference.

1. The
Paper Presentation of Paper
“Using deal.ii through CMAKE to Minimize Gun Metal Casting’s
Uneven Cooling through Computational Methods”
Presented by:
Pratik M. Suryawanshi1
1Department of Mechanical Engineering, New Polytechnic,
Kolhapur, India.

2. CONTENTS
 Introduction
 Problem Definition
 Possible Solutions
 Computational Methods Available
 Open Source Computation
 Assumptions
 Limitations
 Analysis Data
 Mathematical Modelling
 The Code
 Obtained Solutions
 Method Limitations
 Conclusion

3. INTRODUCTION
The Computational Analysis of A Dummy Gun Metal
Casting to identify and Minimize the Defect
formation.
The Presentation is based on the personal analysis
done based on the actual variables studied during
working with the company. The original libraries are
applied for copyright and thus are requested not to be
disclosed yet.
For details contact: Mane Metal Industries, Shivaji
Udyamnagar, Kolhapur, India.

4. PROBLEM DEFINATION
Defect Image
(Actual)
Defect Image
(Similar)

5. PROBLEM DEFINATION
1. Defect Formation near the Mould Surface.
- Three Dimensional Pocket Existence, Unlike Axial Pocket.
2. Induced Porosity in Pockets.
- Sponge Like Surface Developed.
3. Deeper Impact of Defect at the Radial Features.
- Casting had Defect Close to Surface in case of Orthogonal Features.

6. POSSIBLE SOLUTIONS
1. Experimentation Method
- Carrying Out Casting by Various Solutions Proposed in Brain Storming
in Controlled Conditions.
2. Trail and Error Method
- Modifying Parameters in Current Run and Examining them.
3. Computational Method
- Mathematically Modelling the System Considering all The System
Variables and Then Using FEA, Simulation and alike Techniques for
Defect Minimization.

7. COMPUTATIONAL METHODS
1. AUTOCAST :- Designed for Complete Casting Analysis by IIT, Bombay.
2. ProCAST :- Casting Simulation Solution by ESI Group.
3. Flow 3D-CAST :- Complete Simulation & Solution by Flow Science, USA.
4. MAGMASOFT :- Casting Optimization Tool by MAGMA, USA
5. SOLIDCAST :- Thermo-Fluid Analysis of Casting by Finite Solutions

8. OPEN SOURCE COMPUTATION
Command Line Interface (CLI):
1. Deal.ii: Ultimate Library for Computational Analysis.
2. FEniCS: Lacks Customization of Equations and their Numerical Methods.
3. FreeFEM++: Limited by Mathematical Methods.
Graphical User Interface (GUI):
1. Z88Aurora: GUI FEM Tool, Suitable for Elastic Analysis.
2. Elmer FEM Solver: Has Limited Equations and Methods Up it’s sleeve.
3. Calculix: Suitable for Solving PDEs and Pure Mathematical Analysis.

9. ANALYSIS DATA
The following data of Gunmetal is obtained from Mane Metal Industries, Shivaji Udyamnagar, Kolhapur-416008:
Composition – Copper = 88%, Tin = 10%, Zinc = 2%
Gun Metal Density(ρ) = 8.72*103 kg/m3
Modulus of Elasticity = 103 Gpa
Thermal Expansion (at 20°C) = 19.8*10-6 /°C
Thermal Conductivity(k) = 74.8 W/mK
Specific Heat Capacity(c) = 377J/kgK
Casting Emissivity (εc) = 0.5
Mould Emissivity (εm) = 0.8
Melting Point = 1100°C
Casting Temperature (Tc) = 1500°C
Solidus Temperature (Tso) = 854°C
Mould Surface Temperature before Heating (Tm1) = 25°C
Mould Surface Temperature after Heating (Tm2) ≈ 1000°C
Ambient Temperature (Tf) = 29°C
Tensile Strength = 152 MPa
Elongation = 25%

10. ASSUMPTIONS
I. No Mass Transfer
- Analysis is Done After Pouring is Completed.
II. Effective Conductivity
- In Order to Cumulate the Effect of Conduction and Convection.
III. Simple Fillet Mould
- Practical Intricacy is Neglected.
IV. Selection of Dominant Variables
- The Uncertainties and Associated Variables are Assumed to be Constant
or Neglected
V. 2 Degrees of Freedom
- To minimize the Computational Load.

11. MATHEMATICAL MODELLING
General Heat Transfer Equation:
𝛛𝐓
𝛛𝛕
+ 𝐯. 𝛁𝐓 =
𝛒
𝐜𝛒
𝛁 𝟐 𝐓 +
𝐪 𝐯
𝐜𝛒
Fourier-Krichhoff Equation: 𝐪 𝐦 = 𝛂𝐭 𝐓𝐜 − 𝐓 𝐦 ∈ 𝐒 𝐦
𝒒 𝒔 = 𝜶 𝒔 𝑻 𝒄 − 𝑻 𝒇 ∈ 𝑺 𝒔
Stefan-Boltzmann Law for Parallel Pates: 𝜶 𝒓 = 𝟓. 𝟓𝟔 ∗ 𝟏𝟎−𝟖 𝜺 𝒄+𝜺 𝒎−𝜺 𝒄 𝜺 𝒎
𝜺 𝒄 𝜺 𝒎
𝑻 𝒄
𝟒−𝑻 𝒎
𝟒
𝑻 𝒄−𝑻 𝒎
Emperical Relation (Telejko et al. 2009): 𝜶 𝒄 = (𝜶𝒍 − 𝜶 𝒓)𝐞𝐱𝐩(
𝑻 𝒄−𝑻 𝒔𝒐
𝟐𝟎𝟎
)

12. MATHEMATICAL MODELLING
File Structure

13. THE CODE

14. THE CODE

15. THE CODE

16. THE CODE

17. THE CODE

18. OBTAINED SOLUTIONS
Though the Uneven Cooling was the Dominating Factor, there was Another
Factor which Adversely Affected Every Other Industry in this area including
ours.
It was very high ‘Humidity’ and microbes content in the atmosphere, as
Kolhapur received Thirteen Times More Rain and the Udyamnagar was
partially flooded.
This Problem got solved when the Mould was Pre-Heated prior to the pouring of
the molten metal, which was the proposed solution of Mr. P. B. Mane, Owner of
Mane Metal Industries.

19. OBTAINED SOLUTIONS
Defect Identification Defect Minimization

20. METHOD ADVANTAGES
 Virtually Any Computable Equation can be Solved or Approximated.
 The Mesh Creation and Refinement is Completely Flexible and Controlled by
User.
 The Compiler can be used to produce Condition Specific Programs which
can be Limited to a Specific Application.
 Any Numerical Method can be Instructed to the Computer for Computation.
 Output Format is also Controlled by the User.
 Library for Anything can be Created with Customizable Variables.
 Under Single Project, many Analysis can be Grouped.

21. ANALYSIS LIMITATIONS
 Computational Device
 Accuracy of the Analyzation Data
 Lacked Controlled Conditions

22. METHOD LIMITATIONS
 Need of High End Computational Device.
 Powerful CPU and RAM instead of GPU.
 Very Deep Knowledge of C++/C, GNU Compiler, Linux, BASH and CLI.
 Advanced Knowledge of Numerical Methods and Finite Element Analysis.
 Manual Mathematical Modelling and Their Weak Forms.
 CLI Only applicable to Linux.
 Real Time Graphical Analysis is not Possible.

23. CONCLUSION
 An Open Source Solution Method was Proposed.
 Solution Methodology was Elaborated.
 Simulation of a Part of an Actual Condition was Presented.
 Comparison of Various Solution Softwares was given.
 Solution to the Actual Condition was Discussed.

24. REFERENCE
Gunmetal [online] https://en.wikipedia.org/wiki/Gunmetal (October 1, 2019)
Jung-Eui Lee, Heung Nam Han, Kyu Hwan Oh & Jong-Kyu Yoon (1999). A Fully Coupled Analysis of Fluid Flow, Casting Heat
Transfer and Stress in Continuous Round Billet. ISIJ International, Vol, 39 (1999), No. 5, pp, 435-444.
Jung-Eui Lee, Tae-Jung Yeo, Kyu-Hwan Oh, Jong-Kyu Yoon & U-Sok Yoon (2000). Prediction of cracks in continuously cast steel beam
blank through fully coupled analysis of fluid flow, heat transfer, and deformation behaviour of a solidifying shell. Metallurgical and
Materials Transactions A, https://www.researchgate.net/publication/226092530.
Man Yeong Ha, Kuisoon Kim, Kyung Chun Kim & Sung Woo Lee (1994). Transient analysis of thermo-fluid phenomena in twin-roll
continuous casting International Journal of Heat & Mass Transfer Vol. 37, pp.2059-2068, Elsevier Science Ltd.
Mark Samonds & J. Z. Zhu (2000). Coupled Thermal-fluids-stress Analysis of Castings. UES Software Inc., Annapolis, MD, USA.
Moumtez Bensouici, Ahmed Bellaouar, Kamel Talbi' (2009). Numerical Investigation of the Fluid Flow in Continuous Casting Tundish
Using Analysis of RTD Curves, Journal of Iron and Steel Research, International. 2009, 16(2}: 22-29
Nagayasu Bessho, Ryoji Yods, Hisao Yamasaki, Tetsuya Fujii, Tsutomu Nozak & Seiji Takatori (1990). Numerical Analysis of Fluid Flow
in Continuous Casting Mould by Bubble Dispersion Model, ISIJ International, Vol. 31 (1991), No, l, pp. 40-45.
T. Telejko, Z. Malinowski & M. Rywotycki (2009). Analysis of heat transfer and fluid flow in continuous steel casting. Archives of
Metallurgy and Materials, https://www.researchgate.net/publication/270896059.
Ye T. Chou, YA T. Ko, And Manf Yan (1987). Fluid Flow Model for Ceramic Tape Casting. Journel of American Ceramic Society, 70 [lo]
C-280-C-282.

25. THANK - YOU