<ul><li>Department of Metallurgical and Materials Engineering, </li></ul><ul><li>National Institute of Technology – Tiruch...
Contents <ul><li>Introduction </li></ul><ul><li>Objectives </li></ul><ul><li>Execution and Analysis of simulation </li></u...
Introduction  <ul><li>Casting simulations  </li></ul><ul><li>Design any casting process on the computer to check feasibili...
Case studies <ul><li>Littler Diecast Corp . recently redesigned and cast an electrical switch frame for an aerospace custo...
Objectives <ul><li></li></ul><ul><li>Simulate and analyze the sand casting operation of a simple valve component using a s...
Initial design of casting <ul><li></li></ul><ul><li>Casting material -  316 SS (0.08% C, 2% Mn, 0.045% P, 0.03% S, 1% Si, ...
Simulation and analysis of Sand casting process <ul><li></li></ul>Total time for solidification : 4.105 minutes Iso-surfac...
<ul><li></li></ul>
<ul><li>6 risers were designed to address the major regions plagued by porosity. </li></ul><ul><li>All risers were designe...
<ul><li></li></ul>The design was simulated and weights were tabulated: Total Solidification time: 8.207 minutes <ul><li>Is...
 
Simulation and analysis of Investment casting process
After simulation of the casting, the weights were tabulated: Total solidification time: 25.832 minutes (23 seconds pour ti...
Images showing absence of porosities in areas plagued by porosity as seen during the riserless sand casting analysis.
Results & discussions <ul><li></li></ul><ul><li>Sand casting route: </li></ul><ul><ul><li>Without risers porosity develops...
ACKNOWLEDGEMENT <ul><li>Project guide  Dr. S. Raman Sankaranarayanan </li></ul><ul><li>Co-guide  Dr. S. P. Kumaresh Babu  ...
References <ul><li></li></ul><ul><li>B.Ravi, “Scientific methoding by casting simulation: case studies”, 55 th  Indian Fou...
Upcoming SlideShare
Loading in …5
×

Casting simulations - SOLIDCast v8.1 review

3,821 views

Published on

Published in: Design, Business, Technology
0 Comments
2 Likes
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
3,821
On SlideShare
0
From Embeds
0
Number of Embeds
78
Actions
Shares
0
Downloads
0
Comments
0
Likes
2
Embeds 0
No embeds

No notes for slide

Casting simulations - SOLIDCast v8.1 review

  1. 1. <ul><li>Department of Metallurgical and Materials Engineering, </li></ul><ul><li>National Institute of Technology – Tiruchirappalli </li></ul><ul><li>Presentation for B.Tech Project Review </li></ul><ul><li>By </li></ul><ul><li>S. Srivatsan (112107042), S. Gopinath (112107011), and N. V. Harish (112107014) </li></ul><ul><li>Under the guidance of </li></ul><ul><li>Dr. S. Raman Sankaranarayanan and Dr. S. P. Kumaresh Babu </li></ul><ul><li>May 10, 2011 </li></ul>A review of the application of casting simulation packages used in foundries today <ul><li></li></ul>
  2. 2. Contents <ul><li>Introduction </li></ul><ul><li>Objectives </li></ul><ul><li>Execution and Analysis of simulation </li></ul><ul><li>Results and Discussion </li></ul><ul><li>Acknowledgement and References </li></ul><ul><li></li></ul>
  3. 3. Introduction <ul><li>Casting simulations </li></ul><ul><li>Design any casting process on the computer to check feasibility of process. </li></ul><ul><li>Optimize any existing design to increase the quality of the casting while exploring options and methods to cut costs. </li></ul><ul><li>Tests can be done in a small fraction of the actual time taken to build equipment and make sample castings. </li></ul><ul><li>Cast product rejection rate as well as scrap drastically decrease. </li></ul><ul><li>Accurate predictions can be useful in negotiations. </li></ul><ul><li></li></ul>
  4. 4. Case studies <ul><li>Littler Diecast Corp . recently redesigned and cast an electrical switch frame for an aerospace customer using Flow 3D CAST™ due to Porosity problems identified in the previous design. As a result of the new design, the part was cast with minimal scrap, saving thousands of dollars. </li></ul><ul><li>An Aluminium casting was analyzed using AutoCast™ for the cause of frequent failure. The analysis revealed that the current dimensions of the risers used needed to be increased to prevent the formation of isolated hot spots that subsequently led to the formation of porosities. </li></ul>
  5. 5. Objectives <ul><li></li></ul><ul><li>Simulate and analyze the sand casting operation of a simple valve component using a simple initial design. </li></ul><ul><li>Optimize design and parameters to remove shortcomings and improve quality of casting. </li></ul><ul><li>Simulate and analyze the investment casting operation of the same valve component. </li></ul><ul><li>Compare the results of the two simulations and suggest a possible method suited for different scenarios. </li></ul>
  6. 6. Initial design of casting <ul><li></li></ul><ul><li>Casting material - 316 SS (0.08% C, 2% Mn, 0.045% P, 0.03% S, 1% Si, 16% Cr,10% Ni, 2% Mo </li></ul><ul><li>Increased corrosion resistance </li></ul><ul><li>Mo increases resistance to Pitting in Cl - environments like brine, acetic acid vapors, etc. </li></ul>
  7. 7. Simulation and analysis of Sand casting process <ul><li></li></ul>Total time for solidification : 4.105 minutes Iso-surface plot marking areas with 80% density porosities likely to develop at 7 possible locations. Material weights as calculated for riserless valve sand casting Material Mass 316 SS (casting) 5.459kg Silica sand 11.37kg
  8. 8. <ul><li></li></ul>
  9. 9. <ul><li>6 risers were designed to address the major regions plagued by porosity. </li></ul><ul><li>All risers were designed so that their moduli were at least 1.2 times the moduli of the region of the casting fed by them </li></ul><ul><li>Riser efficiencies fixed at 11.34% </li></ul>RISERs 1 & 2 Height 200 mm Diameter 44 mm RISERS 3 to 6 Height 100 mm Diameter 37 mm
  10. 10. <ul><li></li></ul>The design was simulated and weights were tabulated: Total Solidification time: 8.207 minutes <ul><li>Iso-surface plot marking areas with 80% density. </li></ul><ul><li>Porosities totally isolated to risers. </li></ul><ul><li>Almost all of the shrinkage had been arrested from the upper rim of the casting. </li></ul>Material Mass 316 SS (casting) 5.219kg Riser 8.561kg Silica sand 16.991kg
  11. 12. Simulation and analysis of Investment casting process
  12. 13. After simulation of the casting, the weights were tabulated: Total solidification time: 25.832 minutes (23 seconds pour time included) <ul><li>Iso-surface view and cross-sectional view indicating regions with material density of 80% </li></ul><ul><li>Porosities isolated to riser completely </li></ul>Material Mass (considering entire pattern) 316 SS (casting) 22.359kg, for all 4 castings combined Riser 64.073kg (16kg per casting approx.) Investment shell 25.183kg (6.3kg per casting approx.)
  13. 14. Images showing absence of porosities in areas plagued by porosity as seen during the riserless sand casting analysis.
  14. 15. Results & discussions <ul><li></li></ul><ul><li>Sand casting route: </li></ul><ul><ul><li>Without risers porosity develops in several regions in the casting. </li></ul></ul><ul><ul><li>After installation of the risers, the total weight of all metal in risers a high 160% of the casting weight. This could be attributed to the low riser efficiency used (11.34%). This opens up possibilities of exploring insulating or exothermic sleeves to increase the riser efficiencies. </li></ul></ul><ul><ul><li>Overall economic process with no issues on casting size. </li></ul></ul><ul><ul><li>Exploit possibilities of better feeding systems. </li></ul></ul><ul><ul><li>Ideal for economic small scale production. </li></ul></ul><ul><li>Investment casting route: </li></ul><ul><ul><li>Lower process time (considering no. of castings produced per pour). </li></ul></ul><ul><ul><li>Though less weight was needed, the investment shell is generally a more expensive material than molding sand. </li></ul></ul><ul><ul><li>Traces of porosities recorded within the casting material were assumed to be negligible, but are yet to be addressed and removed. </li></ul></ul><ul><ul><li>Intricate shapes, but limited casting size, and in general excellent surface finish. </li></ul></ul><ul><ul><li>More suited for batch production of better quality products. </li></ul></ul>
  15. 16. ACKNOWLEDGEMENT <ul><li>Project guide Dr. S. Raman Sankaranarayanan </li></ul><ul><li>Co-guide Dr. S. P. Kumaresh Babu   </li></ul><ul><li>Project coordinator Dr. V. Muthupandi </li></ul><ul><li>Professor and Head of the Department, Dr. S. Natarajan , </li></ul><ul><li>Finite solutions Inc. </li></ul><ul><li>EDS Technologies, Bangalore </li></ul><ul><li></li></ul>
  16. 17. References <ul><li></li></ul><ul><li>B.Ravi, “Scientific methoding by casting simulation: case studies”, 55 th Indian Foundry Congress, Feb 2007 </li></ul><ul><li>Mark Jolly, Mike cox, Jean-Christophe Gebelin, Sam Jones, and Alexander Cendrowicz, “Fundamentals of Investment Casting (FOCAST)” </li></ul><ul><li>Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003),  Materials and Processes in Manufacturing  (9th ed.), Wiley, ISBN 0-471-65653-4. </li></ul><ul><li>Schleg, Frederick P.; Kohloff, Frederick H.; Sylvia, J. Gerin; American Foundry Society (2003), Technology of Metalcasting, American Foundry Society, ISBN 9780874332575. </li></ul><ul><li>Rao, T. V. (2003),  Metal Casting: Principles and Practice , New Age International, ISBN 9788122408430. </li></ul><ul><li>Kalpakjian, Serope; Schmid, Steven (2006),  Manufacturing Engineering and Technology  (5th ed.), Pearson,  ISBN   0-13-148965-8 . </li></ul><ul><li>Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003),  Materials and Processes in Manufacturing  (9th ed.), Wiley,  ISBN   0-471-65653-4 . </li></ul><ul><li>http://www.keytometals.com/page.aspx?ID=CheckArticle&site=ktn&NM=204 </li></ul><ul><li>Rao, Posinasetti Nageswara (1999),  Manufacturing technology: foundry, forming and welding  (2nd ed.), Tata McGraw-Hill,  ISBN   9780074631805 . </li></ul>

×