There is an increasing demand in manufacturing environment for the best quality of casting
products at the right time and quantity. In order to survive in the competitive market and to achieve
customer satisfaction trial-and-error method to produce defect free casting products from design to
manufacturing is too costly and not effective [1]. Modernization is the only key to improve casting quality
and productivity. This paper discusses the simulation process of casting solidification with the AutoCAST-X
software of a intricate shape small size casting of LM6 (Al alloy) metal. With the help of simulation study
hot spot in the casting has been identified. This has immensely helped in locating the optimum position and
size of the feeder required. This paper also shows the application of feeding aids as exothermic sleeve. The
simulation study has shown the improvement in feeding yield and quality of the casting.
Image segmentation, Rough set Theory, Game Theory, Image processingijsrd.com
Valve is most common part for every Fluid handling industry. Production of cast Valve is critical because, in today's competitive world customer wants fast and accurate Component. Computer simulation tools are used to reduce a time for development of a component. Simulation software is mainly used to visualize a complete process of solidification, which is not possible in real casting process. Defects such as shrinkage porosity, gas porosity, unfilled mould, cold shut etc. can also graphically observe with simulation. Initially CAD model of impeller has been prepared, then export for simulation. Many researchers reported that about 90% of the defects in castings are due to wrong design of gating system and only 10% due to manufacturing problems. Casting simulation process can able to solve these problems. To study the solidification behavior and detection of hot spots in castings with the help of casting simulation software. The simulated results also compared with the experimental works.
Steelcast limited industrial training reportaman1312
Steelcast limited is an India-based company. The company is engaged in the business of steel casting . Its product include carbon steel , low alloy steel , high alloy steel , hadfield manganese steel , and other grade of wear and abrasion resistant steel casting produced by sand molding and shell moulding process . The Company caters to industries , such as earthmoving equipment manufacturing , heavy electrical equipment manufacturing , mining , minerals processing equipment manufacturers , valve manufacturers and general engineering equipment manufacturers.
Image segmentation, Rough set Theory, Game Theory, Image processingijsrd.com
Valve is most common part for every Fluid handling industry. Production of cast Valve is critical because, in today's competitive world customer wants fast and accurate Component. Computer simulation tools are used to reduce a time for development of a component. Simulation software is mainly used to visualize a complete process of solidification, which is not possible in real casting process. Defects such as shrinkage porosity, gas porosity, unfilled mould, cold shut etc. can also graphically observe with simulation. Initially CAD model of impeller has been prepared, then export for simulation. Many researchers reported that about 90% of the defects in castings are due to wrong design of gating system and only 10% due to manufacturing problems. Casting simulation process can able to solve these problems. To study the solidification behavior and detection of hot spots in castings with the help of casting simulation software. The simulated results also compared with the experimental works.
Steelcast limited industrial training reportaman1312
Steelcast limited is an India-based company. The company is engaged in the business of steel casting . Its product include carbon steel , low alloy steel , high alloy steel , hadfield manganese steel , and other grade of wear and abrasion resistant steel casting produced by sand molding and shell moulding process . The Company caters to industries , such as earthmoving equipment manufacturing , heavy electrical equipment manufacturing , mining , minerals processing equipment manufacturers , valve manufacturers and general engineering equipment manufacturers.
Optimization of Metal Removal Rateon Cylindrical Grinding For Is 319 Brass Us...IJERA Editor
Cylindrical grinding is one of the most important metal cutting processes used extensively in the Metal finishing operations. Metal removal rate and surface finish are the important output responses in the production with respect to quantity and quality respectively. The objective of this paper is to arrive at the optimal grinding conditions that will maximize metal removal rate when grinding IS 319 brass. Empirical models were developed using design of experiments by Taguchi L9 Orthogonal Array and the adequacy of the developed model is tested with ANOVA.
It is a final year project report for mechanical engineering. This report is a study on the erosion of various materials using slurry (water and silica) and various parameters which affect that.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
We would send hard copy of Journal by speed post to the address of correspondence author after online publication of paper.
We will dispatched hard copy to the author within 7 days of date of publication
Charge Weld Prediction and Minimization in Extrusion - Choose ahead, choose A...Tommaso Pinter
Today with FE simulation we can help extrusion companies to predict and reduce front scrap thus allowing them to precisely estimate the production cost of a drawing profile before the contract is signed and the die is ordered.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
Wally s3 e cold_rolling_mills_strip_processing_linesWally Heydendael
Using liquid nitrogen as a coolant in final or skin pass cold rolling can dramatically increase
productivity by raising throughput, improving product quality and reducing rejects. G. Plicht and H.
Schillak of Air Products, and H. Höfinghoff and T. Demski of C.D. Wälzholz, describe the new Air
Products cool rolling technology.
Isolation and Identification High-Biological Activity Bacteria in Yogurt Qua...IJMER
Six strains of lactic bacteria and seven strains of acetic bacteria which were isolated from
fermented food. The screening secured one strain of lactic acid bacterium LB4 which carried strong
probiotic activity and one strain of acetic acid bacterium AB7 which was capable to generate high
glucuronic acid. Activities of probiotic and glucuronic acid were useful biological activities for health
protection and enhancing. The results of DNA sequencing showed LB4 was similar to Lactobacillus
acidophilus and AB7 was similar to Gluconacetobacter nataicola with 100% of similar proportion. Both
of these bacteria were safe that could be used in food fermentation.Six strains of lactic bacteria and seven strains of acetic bacteria which were isolated from
fermented food. The screening secured one strain of lactic acid bacterium LB4 which carried strong
probiotic activity and one strain of acetic acid bacterium AB7 which was capable to generate high
glucuronic acid. Activities of probiotic and glucuronic acid were useful biological activities for health
protection and enhancing. The results of DNA sequencing showed LB4 was similar to Lactobacillus
acidophilus and AB7 was similar to Gluconacetobacter nataicola with 100% of similar proportion. Both
of these bacteria were safe that could be used in food fermentation.
Optimization of Metal Removal Rateon Cylindrical Grinding For Is 319 Brass Us...IJERA Editor
Cylindrical grinding is one of the most important metal cutting processes used extensively in the Metal finishing operations. Metal removal rate and surface finish are the important output responses in the production with respect to quantity and quality respectively. The objective of this paper is to arrive at the optimal grinding conditions that will maximize metal removal rate when grinding IS 319 brass. Empirical models were developed using design of experiments by Taguchi L9 Orthogonal Array and the adequacy of the developed model is tested with ANOVA.
It is a final year project report for mechanical engineering. This report is a study on the erosion of various materials using slurry (water and silica) and various parameters which affect that.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
We would send hard copy of Journal by speed post to the address of correspondence author after online publication of paper.
We will dispatched hard copy to the author within 7 days of date of publication
Charge Weld Prediction and Minimization in Extrusion - Choose ahead, choose A...Tommaso Pinter
Today with FE simulation we can help extrusion companies to predict and reduce front scrap thus allowing them to precisely estimate the production cost of a drawing profile before the contract is signed and the die is ordered.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
Wally s3 e cold_rolling_mills_strip_processing_linesWally Heydendael
Using liquid nitrogen as a coolant in final or skin pass cold rolling can dramatically increase
productivity by raising throughput, improving product quality and reducing rejects. G. Plicht and H.
Schillak of Air Products, and H. Höfinghoff and T. Demski of C.D. Wälzholz, describe the new Air
Products cool rolling technology.
Isolation and Identification High-Biological Activity Bacteria in Yogurt Qua...IJMER
Six strains of lactic bacteria and seven strains of acetic bacteria which were isolated from
fermented food. The screening secured one strain of lactic acid bacterium LB4 which carried strong
probiotic activity and one strain of acetic acid bacterium AB7 which was capable to generate high
glucuronic acid. Activities of probiotic and glucuronic acid were useful biological activities for health
protection and enhancing. The results of DNA sequencing showed LB4 was similar to Lactobacillus
acidophilus and AB7 was similar to Gluconacetobacter nataicola with 100% of similar proportion. Both
of these bacteria were safe that could be used in food fermentation.Six strains of lactic bacteria and seven strains of acetic bacteria which were isolated from
fermented food. The screening secured one strain of lactic acid bacterium LB4 which carried strong
probiotic activity and one strain of acetic acid bacterium AB7 which was capable to generate high
glucuronic acid. Activities of probiotic and glucuronic acid were useful biological activities for health
protection and enhancing. The results of DNA sequencing showed LB4 was similar to Lactobacillus
acidophilus and AB7 was similar to Gluconacetobacter nataicola with 100% of similar proportion. Both
of these bacteria were safe that could be used in food fermentation.
Low Cost Self-assistive Voice Controlled Technology for Disabled PeopleIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Resolution of human arm redundancy in point tasks by synthesizing two criteriaIJMER
The human arm is kinematically redundant in the task of pointing. As a result, multiple arm
configurations can be used to complete a pointing task in which the tip of the index finger is brought to a
preselected point in a 3D space. The authors have developed a four degrees of freedom (DOF)model of the
human arm with synthesis of two redundancy resolution criteria that were developed as an analytical tool
for studying the positioning tasks. The two criteria were: (1) minimizing the angular joint displacement
(Minimal Angular Displacement - MAD) and (2) averaging the limits of the shoulder joint range (Joint
Range Availability - JRA). As part of the experimental protocol conducted with ten subjects, the kinematics
of the human arm was acquired with a motion capturing system in a 3D space. The redundant joint angles
predicted by a equally weighted model synthesizing the MAD and JRA criteria resulted with a linear
correlation with the experimental data (slope=0.88; offset=1⁰; r
2=0.52). Given the experiment protocol,
individual criterion showed weaker correlation with experimental data (MAD slope=0.57, offset=14⁰,
r
2=0.36 or JRA slope=0.84, offset=-1⁰, r
2=0.45). Solving the inverse kinematics problem of articulated
redundant serials mechanism such as a human or a robotic arm has applications in fields of human-robot
interaction and wearable robotics, ergonomics, and computer graphics animation.
In Multi-Hop Routing identifying trusted paths through TARF in Wireless sens...IJMER
The multi-hop routing in wireless sensor networks (WSNs) highly vulnerable against
identity cheating through replaying routing data. An attacker can uses this drawback to launch
various serious or even disturbing attacks against the routing protocols, like sinkhole attacks,
wormhole attacks and Sybil attacks. The situation is further forced by mobile and unkind
network conditions. old cryptographic techniques or efforts at developing trust-aware routing
protocols do not effectively address this serious problem. To secure the WSNs against attackers
misdirecting the multi-hop routing, we have designed and implemented TARF, a robust trust-aware
routing framework for dynamic WSNs. Without tight time synchronization or known geographic
information, TARF provides trustworthy and energy-efficient route. Most importantly, TARF proves
effective against those dangerous attacks developed out of identity cheat; the flexibility of
TARF is verified through extensive evaluation with both simulation and empirical experiments on
large-scale WSNs under various scenarios including mobile and RF-shielding network conditions.
Further, we have implemented allow-overhead TARF module in TinyOS; as demonstrated, this
implementation can be included into existing routing protocols with the little effort. Based on
TARF, we also demonstrated a proof-of-concept mobile target detection application that functions
well against an anti-detection mechanism. this
implementation can be included into existing routing protocols with the little effort. Based on
TARF, we also demonstrated a proof-of-concept mobile target detection application that functions
well against an anti-detection mechanism.
Upgrading of Low Temperature Solar Heat with Cascade Vapor Compression and Ab...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
AC-DC-AC-DC Converter Using Silicon Carbide Schottky DiodeIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Earthquake Resistant Design of Low-Rise Open Ground Storey Framed BuildingIJMER
Presence of infill walls in the frames alters the behavior of the building under lateral loads.
However, it is common industry practice to ignore the stiffness of infill wall for analysis of framed
building. Engineers believe that analysis without considering infill stiffness leads to a conservative
design. An existing RC framed building (G+3) with open ground storey located in Seismic Zone-V is
considered for this study. This building is analyzed for two different cases: (a) considering both infill
mass and infill stiffness and (b) considering infill mass but without considering infill stiffness. Two
separate models were generated using commercial software SAP2000. Infill weights were modelled
through applying static dead load and corresponding masses considered from this dead load for
dynamic analyses. Infill stiffness was modelled using a diagonal strut approach. Two different support
conditions, namely fixed end support condition and pinned end support condition, are considered to
check the effect of support conditions in the multiplication factors. Linear and non-linear analyses were
carried out for the models and the results were compared.
CFD Analysis and Fabrication of Aluminium Cenosphere CompositesIJMER
Metal matrix composites are engineered materials with a combination of two or more
dissimilar materials, to obtain enhanced properties. Aluminium alloys reinforced with ceramic
particles exhibit superior mechanical properties when compared to unreinforced aluminium alloys and
hence are candidate for engineering applications. In the present investigation aluminium alloy is used
as the matrix and cenosphere as the reinforcing material. The hybrid metal matrix composite is
produced using conventional foundry techniques by casting route. The cenosphere is to be added in
2%, 4% and 6% by volume and also with the influence of the particle size of cenosphere, to the molten
metal with Magnesium, which is the main parameter for the wet ability of cenosphere and aluminium
alloy. The hybrid composite is to be tested for hardness, density, mechanical properties and impact
strength. The density decreases with increase in cenosphere content. The impact strength increases
with increase in cenosphere content. The resistances to dry wear and slurry erosive wear increases
with increase in cenosphere content and hence this material can be used as bearing material. This
composite material being less dense than aluminium can therefore be used in place of conventional
aluminium alloys in aircraft components
CFD Analysis and Fabrication of Aluminium Cenosphere Composites
Similar to Minimization of Shrinkage Porosity in A Sand Casting Process By Simulation In AUTOCAST-X Software with Experimental Validation by Destructive testing
A practical approach to eliminate defects in gravity die cast al alloy castin...eSAT Journals
Abstract
This paper deals with elimination of defects in aluminium alloy castings produced by gravity die casting process. The main intention of work is to investigate the defects and improve quality of a gravity die cast component using Computer Aided Casting Simulation Software. In this study an industrial gravity casting die is used which was producing defective components. The die and components produced by the die are studied to eliminate the defects using virtual simulations. The defects in the components are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons for the defects are analyzed as either improper selection of process parameters, or improper design of gating and risering system. SOLIDCast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. The work is carried out in two stages. In first stage, few test castings are produced by modifying the process parameters (pouring temperature, pouring time, pre heat and alloy type) and results are compared with simulation results produced using same parameters. The pouring and simulation results are observed to be in good accordance with each other. In second stage, number of virtual iterations of casting is performed by changing riser dimensions. It was found from the simulation results that riser with 35mm diameter is required to produce casting with zero defects. The die is modified accordingly with the simulation results and metal is poured. The castings produced are observed to be sound and contain no defects; and also it is verified that solidification simulation helps in locating the defects, eliminating them and ultimately improving the quality of castings without any shop-floor trails.
Keywords: Aluminum-Alloys, Casting Defects, Gravity Die Casting, Material Density and SOLIDCast Simulation
FE Analysis for Investment Casting and Computer Simulation: A Reviewijsrd.com
In the present paper a review for the experimental and finite element analysis techniques is adopted for Investment casting. Experimental Data taken for Solidification of investment Casting is modeled and meshed initially then validation is followed by comparing the experimental and modeled results. This helps to optimize the design criteria for investment casting. To overcome the problem of current gating /riser system and by comparing simulation results of optimized casting model with that of original model we can reduce the shrinkage porosity.
NEW APPROACH TO CASTING DEFECTS CLASSIFICATION AND OPTIMIZATION BY MAGMA SOFTIAEME Publication
Foundry industry suffers from poor quality and productivity due to the large number of process parameters, combined with lower penetration of manufacturing automation and shortage of skilled workers compared to other industries. Global buyers demand defect-free castings and strict delivery schedule, which foundries are finding it very difficult to meet.
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Similar to Minimization of Shrinkage Porosity in A Sand Casting Process By Simulation In AUTOCAST-X Software with Experimental Validation by Destructive testing (20)
A Study on Translucent Concrete Product and Its Properties by Using Optical F...IJMER
- Translucent concrete is a concrete based material with light-transferring properties,
obtained due to embedded light optical elements like Optical fibers used in concrete. Light is conducted
through the concrete from one end to the other. This results into a certain light pattern on the other
surface, depending on the fiber structure. Optical fibers transmit light so effectively that there is
virtually no loss of light conducted through the fibers. This paper deals with the modeling of such
translucent or transparent concrete blocks and panel and their usage and also the advantages it brings
in the field. The main purpose is to use sunlight as a light source to reduce the power consumption of
illumination and to use the optical fiber to sense the stress of structures and also use this concrete as an
architectural purpose of the building
Developing Cost Effective Automation for Cotton Seed DelintingIJMER
A low cost automation system for removal of lint from cottonseed is to be designed and
developed. The setup consists of stainless steel drum with stirrer in which cottonseeds having lint is mixed
with concentrated sulphuric acid. So lint will get burn. This lint free cottonseed treated with lime water to
neutralize acidic nature. After water washing this cottonseeds are used for agriculter purpose
Study & Testing Of Bio-Composite Material Based On Munja FibreIJMER
The incorporation of natural fibres such as munja fiber composites has gained
increasing applications both in many areas of Engineering and Technology. The aim of this study is to
evaluate mechanical properties such as flexural and tensile properties of reinforced epoxy composites.
This is mainly due to their applicable benefits as they are light weight and offer low cost compared to
synthetic fibre composites. Munja fibres recently have been a substitute material in many weight-critical
applications in areas such as aerospace, automotive and other high demanding industrial sectors. In
this study, natural munja fibre composites and munja/fibreglass hybrid composites were fabricated by a
combination of hand lay-up and cold-press methods. A new variety in munja fibre is the present work
the main aim of the work is to extract the neat fibre and is characterized for its flexural characteristics.
The composites are fabricated by reinforcing untreated and treated fibre and are tested for their
mechanical, properties strictly as per ASTM procedures.
Hybrid Engine (Stirling Engine + IC Engine + Electric Motor)IJMER
Hybrid engine is a combination of Stirling engine, IC engine and Electric motor. All these 3 are
connected together to a single shaft. The power source of the Stirling engine will be a Solar Panel. The aim of
this is to run the automobile using a Hybrid engine
Fabrication & Characterization of Bio Composite Materials Based On Sunnhemp F...IJMER
The present day technology demands eco-friendly developments. In this era the
composite material are playing a vital roal in different field of Engineering .The composite materials
are using as a principle materials. Nowaday the composite materials are utilizing as a important
component of engineering field .Where as the importance of the applications of composites is well
known, but thrust on the use of natural fibres in it for reinforcement has been given priority for some
times. But changing from synthetic fibres to natural fibres provides only half green-composites. A
partial green composite will be achieved if the matrix component is also eco-friendly. Keeping this in
view, a detailed literature surveyed has been carried out through various issues of the Journals
related to this field. The material systems used are sunnhemp fibres. Some epoxy and hardener has
been also added for stability and drying of the bio-composites. Various graphs and bar-charts are
super-imposed on each other for comparison among themselves and Graphs is plotted on MAT LAB
and ORIGIN 6.0 software. To determining tensile strengths, Various properties for different biocomposites
have been compared among themselves. Comparison of the behaviour of bio-composites of
this work has been also compare with other works. The bio-composites developed in this work are
likely to get applications in fall ceilings, partitions, bio-degradable packagings, automotive interiors,
sports things (e.g. rackets, nets, etc.), toys etc.
Geochemistry and Genesis of Kammatturu Iron Ores of Devagiri Formation, Sandu...IJMER
The Greenstone belts of Karnataka are enriched in BIFs in Dharwar craton, where Iron
formations are confined to the basin shelf, clearly separated from the deeper-water iron formation that
accumulated at the basin margin and flanking the marine basin. Geochemical data procured in terms of
major, trace and REE are plotted in various diagrams to interpret the genesis of BIFs. Al2O3, Fe2O3 (T),
TiO2, CaO, and SiO2 abundances and ratios show a wide variation. Ni, Co, Zr, Sc, V, Rb, Sr, U, Th,
ΣREE, La, Ce and Eu anomalies and their binary relationships indicate that wherever the terrigenous
component has increased, the concentration of elements of felsic such as Zr and Hf has gone up. Elevated
concentrations of Ni, Co and Sc are contributed by chlorite and other components characteristic of basic
volcanic debris. The data suggest that these formations were generated by chemical and clastic
sedimentary processes on a shallow shelf. During transgression, chemical precipitation took place at the
sediment-water interface, whereas at the time of regression. Iron ore formed with sedimentary structures
and textures in Kammatturu area, in a setting where the water column was oxygenated.
Experimental Investigation on Characteristic Study of the Carbon Steel C45 in...IJMER
In this paper, the mechanical characteristics of C45 medium carbon steel are investigated
under various working conditions. The main characteristic to be studied on this paper is impact toughness
of the material with different configurations and the experiment were carried out on charpy impact testing
equipment. This study reveals the ability of the material to absorb energy up to failure for various
specimen configurations under different heat treated conditions and the corresponding results were
compared with the analysis outcome
Non linear analysis of Robot Gun Support Structure using Equivalent Dynamic A...IJMER
Robot guns are being increasingly employed in automotive manufacturing to replace
risky jobs and also to increase productivity. Using a single robot for a single operation proves to be
expensive. Hence for cost optimization, multiple guns are mounted on a single robot and multiple
operations are performed. Robot Gun structure is an efficient way in which multiple welds can be done
simultaneously. However mounting several weld guns on a single structure induces a variety of
dynamic loads, especially during movement of the robot arm as it maneuvers to reach the weld
locations. The primary idea employed in this paper, is to model those dynamic loads as equivalent G
force loads in FEA. This approach will be on the conservative side, and will be saving time and
subsequently cost efficient. The approach of the paper is towards creating a standard operating
procedure when it comes to analysis of such structures, with emphasis on deploying various technical
aspects of FEA such as Non Linear Geometry, Multipoint Constraint Contact Algorithm, Multizone
meshing .
Static Analysis of Go-Kart Chassis by Analytical and Solid Works SimulationIJMER
This paper aims to do modelling, simulation and performing the static analysis of a go
kart chassis consisting of Circular beams. Modelling, simulations and analysis are performed using 3-D
modelling software i.e. Solid Works and ANSYS according to the rulebook provided by Indian Society of
New Era Engineers (ISNEE) for National Go Kart Championship (NGKC-14).The maximum deflection is
determined by performing static analysis. Computed results are then compared to analytical calculation,
where it is found that the location of maximum deflection agrees well with theoretical approximation but
varies on magnitude aspect.
In récent year various vehicle introduced in market but due to limitation in
carbon émission and BS Séries limitd speed availability vehicle in the market and causing of
environnent pollution over few year There is need to decrease dependancy on fuel vehicle.
bicycle is to be modified for optional in the future To implement new technique using change in
pedal assembly and variable speed gearbox such as planetary gear optimise speed of vehicle
with variable speed ratio.To increase the efficiency of bicycle for confortable drive and to
reduce torque appli éd on bicycle. we introduced epicyclic gear box in which transmission done
throgh Chain Drive (i.e. Sprocket )to rear wheel with help of Epicyclical gear Box to give
number of différent Speed during driving.To reduce torque requirent in the cycle with change in
the pedal mechanism
Integration of Struts & Spring & Hibernate for Enterprise ApplicationsIJMER
The proposal of this paper is to present Spring Framework which is widely used in
developing enterprise applications. Considering the current state where applications are developed using
the EJB model, Spring Framework assert that ordinary java beans(POJO) can be utilize with minimal
modifications. This modular framework can be used to develop the application faster and can reduce
complexity. This paper will highlight the design overview of Spring Framework along with its features that
have made the framework useful. The integration of multiple frameworks for an E-commerce system has
also been addressed in this paper. This paper also proposes structure for a website based on integration of
Spring, Hibernate and Struts Framework.
Microcontroller Based Automatic Sprinkler Irrigation SystemIJMER
Microcontroller based Automatic Sprinkler System is a new concept of using
intelligence power of embedded technology in the sprinkler irrigation work. Designed system replaces
the conventional manual work involved in sprinkler irrigation to automatic process. Using this system a
farmer is protected against adverse inhuman weather conditions, tedious work of changing over of
sprinkler water pipe lines & risk of accident due to high pressure in the water pipe line. Overall
sprinkler irrigation work is transformed in to a comfortableautomatic work. This system provides
flexibility & accuracy in respect of time set for the operation of a sprinkler water pipe lines. In present
work the author has designed and developed an automatic sprinkler irrigation system which is
controlled and monitored by a microcontroller interfaced with solenoid valves.
On some locally closed sets and spaces in Ideal Topological SpacesIJMER
In this paper we introduce and characterize some new generalized locally closed sets
known as
δ
ˆ
s-locally closed sets and spaces are known as
δ
ˆ
s-normal space and
δ
ˆ
s-connected space and
discussed some of their properties
Intrusion Detection and Forensics based on decision tree and Association rule...IJMER
This paper present an approach based on the combination of, two techniques using
decision tree and Association rule mining for Probe attack detection. This approach proves to be
better than the traditional approach of generating rules for fuzzy expert system by clustering methods.
Association rule mining for selecting the best attributes together and decision tree for identifying the
best parameters together to create the rules for fuzzy expert system. After that rules for fuzzy expert
system are generated using association rule mining and decision trees. Decision trees is generated for
dataset and to find the basic parameters for creating the membership functions of fuzzy inference
system. Membership functions are generated for the probe attack. Based on these rules we have
created the fuzzy inference system that is used as an input to neuro-fuzzy system. Fuzzy inference
system is loaded to neuro-fuzzy toolbox as an input and the final ANFIS structure is generated for
outcome of neuro-fuzzy approach. The experiments and evaluations of the proposed method were
done with NSL-KDD intrusion detection dataset. As the experimental results, the proposed approach
based on the combination of, two techniques using decision tree and Association rule mining
efficiently detected probe attacks. Experimental results shows better results for detecting intrusions as
compared to others existing methods
Natural Language Ambiguity and its Effect on Machine LearningIJMER
"Natural language processing" here refers to the use and ability of systems to process
sentences in a natural language such as English, rather than in a specialized artificial computer
language such as C++. The systems of real interest here are digital computers of the type we think of as
personal computers and mainframes. Of course humans can process natural languages, but for us the
question is whether digital computers can or ever will process natural languages. We have tried to
explore in depth and break down the types of ambiguities persistent throughout the natural languages
and provide an answer to the question “How it affects the machine translation process and thereby
machine learning as whole?” .
Today in era of software industry there is no perfect software framework available for
analysis and software development. Currently there are enormous number of software development
process exists which can be implemented to stabilize the process of developing a software system. But no
perfect system is recognized till yet which can help software developers for opting of best software
development process. This paper present the framework of skillful system combined with Likert scale. With
the help of Likert scale we define a rule based model and delegate some mass score to every process and
develop one tool name as MuxSet which will help the software developers to select an appropriate
development process that may enhance the probability of system success.
Material Parameter and Effect of Thermal Load on Functionally Graded CylindersIJMER
The present study investigates the creep in a thick-walled composite cylinders made
up of aluminum/aluminum alloy matrix and reinforced with silicon carbide particles. The distribution
of SiCp is assumed to be either uniform or decreasing linearly from the inner to the outer radius of
the cylinder. The creep behavior of the cylinder has been described by threshold stress based creep
law with a stress exponent of 5. The composite cylinders are subjected to internal pressure which is
applied gradually and steady state condition of stress is assumed. The creep parameters required to
be used in creep law, are extracted by conducting regression analysis on the available experimental
results. The mathematical models have been developed to describe steady state creep in the composite
cylinder by using von-Mises criterion. Regression analysis is used to obtain the creep parameters
required in the study. The basic equilibrium equation of the cylinder and other constitutive equations
have been solved to obtain creep stresses in the cylinder. The effect of varying particle size, particle
content and temperature on the stresses in the composite cylinder has been analyzed. The study
revealed that the stress distributions in the cylinder do not vary significantly for various combinations
of particle size, particle content and operating temperature except for slight variation observed for
varying particle content. Functionally Graded Materials (FGMs) emerged and led to the development
of superior heat resistant materials.
Energy Audit is the systematic process for finding out the energy conservation
opportunities in industrial processes. The project carried out studies on various energy conservation
measures application in areas like lighting, motors, compressors, transformer, ventilation system etc.
In this investigation, studied the technical aspects of the various measures along with its cost benefit
analysis.
Investigation found that major areas of energy conservation are-
1. Energy efficient lighting schemes.
2. Use of electronic ballast instead of copper ballast.
3. Use of wind ventilators for ventilation.
4. Use of VFD for compressor.
5. Transparent roofing sheets to reduce energy consumption.
So Energy Audit is the only perfect & analyzed way of meeting the Industrial Energy Conservation.
An Implementation of I2C Slave Interface using Verilog HDLIJMER
The focus of this paper is on implementation of Inter Integrated Circuit (I2C) protocol
following slave module for no data loss. In this paper, the principle and the operation of I2C bus protocol
will be introduced. It follows the I2C specification to provide device addressing, read/write operation and
an acknowledgement. The programmable nature of device provide users with the flexibility of configuring
the I2C slave device to any legal slave address to avoid the slave address collision on an I2C bus with
multiple slave devices. This paper demonstrates how I2C Master controller transmits and receives data to
and from the Slave with proper synchronization.
The module is designed in Verilog and simulated in ModelSim. The design is also synthesized in Xilinx
XST 14.1. This module acts as a slave for the microprocessor which can be customized for no data loss.
Discrete Model of Two Predators competing for One PreyIJMER
This paper investigates the dynamical behavior of a discrete model of one prey two
predator systems. The equilibrium points and their stability are analyzed. Time series plots are obtained
for different sets of parameter values. Also bifurcation diagrams are plotted to show dynamical behavior
of the system in selected range of growth parameter
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Minimization of Shrinkage Porosity in A Sand Casting Process By Simulation In AUTOCAST-X Software with Experimental Validation by Destructive testing
1. International
OPEN ACCESS Journal
Of Modern Engineering Research (IJMER)
| IJMER | ISSN: 2249–6645 | www.ijmer.com | Vol. 4 | Iss. 5| May. 2014 | 18|
Minimization of Shrinkage Porosity in A Sand Casting Process
By Simulation In AUTOCAST-X Software with Experimental
Validation by Destructive testing
A.K.Gajbhiye1
, C.M.Choudhari2
, D.N.Raut3
, B.E.Narkhede4
, B.M.Bhandarkar5
1
(Student, M. Tech., Department of Production Engineering, V.J.T.I. Mumbai, India.)
2
(Professor, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, India.)
3
(Professor and Dean Administration, Department of Production Engineering, V.J.T.I., Mumbai, India.)
4
(Professor and Head, Department of Production Engineering, V.J.T.I., Mumbai, India)
5
(Chairman, Indian Institution of Industrial Engineering {IIIE}, Navi Mumbai, India)
I. INTRODUCTION
Metal casting is one of the oldest manufacturing processes used to manufacture the complex shape
objects. There is an increasing demand in manufacturing environment for the best quality of casting products
at the right time and quantity. In order to survive in the competitive market and to achieve customer
satisfaction trial-and-error method to produce defect free casting products from design to manufacturing is too
costly and not effective[1]. Numerical simulation provides a powerful means of analyzing various physical
phenomena occurring during casting processes. It gives an insight into the details of fluid flow, heat transfer
and solidification. The goal of such simulations is to help shorten the design process and optimize casting
parameters to reduce scrap, use less energy and, of course, make better castings. Shrinkage is a major defect in
sand casting and often becomes a cause of casting rejections and rework in casting industry. Shrinkage is a
phenomenon concerning the reduction in the size of a casting during its transition from a liquid to a solid
state. The volume in both the liquid and solid phases changes under the influence of temperature. The
difference in density of the liquid and solid phases, which causes a significant difference in the volume of these
phases, should be taken into account. The phenomenon of metal shrinkage has a substantial impact on the
quality of castings. The phenomenon of casting shrinkage cannot be avoided. It is however possible to
minimize the occurrence of its negative effects on the casting. In order to achieve this computer simulation is
inevitably necessary. Various simulation software’s based on different numerical techniques such as Finite
Element Method (FEM), Vector Element Method (VEM), Finite Difference Method (FDM), Finite Volume
Method (FVM), Vector Gradient Method (VGM) etc. are available to find these defects and minimize them.
AutoCAST which is based on VGM is providing easy computer interface to deal with these issues for entire
method designing of casting. Hence it become customary for a foundry engineer or a product designer to
anticipate all issues prevailing to the potential defects in the casting and take a suitable measure in advance to
minimize them. Hence one best way is to use the casting solidification simulation practices. The simulations
were compared with experimental trials to ensure that the simulation results are in good agreement with the
experimental trials.
Abstract: There is an increasing demand in manufacturing environment for the best quality of casting
products at the right time and quantity. In order to survive in the competitive market and to achieve
customer satisfaction trial-and-error method to produce defect free casting products from design to
manufacturing is too costly and not effective [1]. Modernization is the only key to improve casting quality
and productivity. This paper discusses the simulation process of casting solidification with the AutoCAST-X
software of a intricate shape small size casting of LM6 (Al alloy) metal. With the help of simulation study
hot spot in the casting has been identified. This has immensely helped in locating the optimum position and
size of the feeder required. This paper also shows the application of feeding aids as exothermic sleeve. The
simulation study has shown the improvement in feeding yield and quality of the casting.
Keywords: AutoCAST-X, Casting, Design, Feeding aid., Hotspot, LM6(Al Alloy), Shrinkage, Simulation
Software.
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II. LITERATURE REVIEW
From the existing and recent literature citations it is found that the currently available casting
solidification simulation software’s have a lot of capabilities to analyse the defects and have received
considerable attention from researchers in the past. Various research and their finding related to improvement
in casting quality and minimization of shrinkage defects using simulation software has been mentioned in this
section. Yeh-Liang Hsu et. al. [2] carried the casting simulation using ProCAST software for aluminium
wheels. Here, shrinkage index was used to predict the casting quality of aluminum wheels to find the optimal
parameters affecting the casting process. Thoguluva R. V. et. al. [3] studied the role, prospects, and
application of computers in foundries to improve casting quality and productivity. Author has mentioned about
the different casting simulation softwares available. Prabhakara Rao et. al. [4] has discussed about the
simulation process of casting solidification with the aid of an example, which will help the foundry industries
to optimize the design parameters, better understand the mould filling and temperature history of the
solidifying castings to identify the defects with the aid of obtained time-temperature contours using ProCAST
softwares. Author has also mentioned the limitation of the conventional sand casting and gating design. T.
Ramu et. al. [5] has developed a solid model of flywheel by using PRO-E and exported it to MAGAMA-5
software to simulate the model and to develop the pattern so as to avoid the foundry defects which will help in
reducing the manufacturing cost. A. Kermanpur et. al. [6] studied the metal flow and solidification behaviors
in a multi-cavity casting mould of two automotive cast parts using FLOW-3D simulation software and
validated the simulation model against the experimental observations showing that the four-cavity mould is
more suitable than the three-cavity one, in getting a more uniform casting quality for all cast parts. The
simulation model was also able to study the effects of several casting parameters including the melt superheat,
pouring time (velocity), mould surface roughness, gating design, and the mould configuration for the quality
and soundness of automotive cast parts. T.Nandi et. al. [7] studied plate castings to investigate the
solidification behavior of aluminum alloy (LM6) with different sizes of feeders based on conventional methods
and computer simulation technique. Author has concluded that the application of casting simulation software
in the foundries not only minimizes the wastages of resources but also enhances the quality and yield of
castings, which implies higher value addition and lower production cost. In the present work intricate shape
small size casting of LM6 (Al alloy) is taken for study. Design calculations using conventional methods has
been done. designed calculation has been verified by performing solidification simulation using AutoCAST
software.
III. PROBLEM DEFINITION
Fig. 1. below shows the different views of casting pattern with various allowances. The component
shown in Fig. 1. has, Volume of casting, Vc = 201800 mm3, Surface area of casting, SAc = 29000mm2 and
Casting modulus Mc = 6.9586 mm. Here, non-pressurized gating ratio as 1:2:2 is used.
Fig.1. wooden pattern with allowances for casting
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Initially design calculations were carried theoretically to find the various dimensions. Design
calculations begin with calculation for pattern allowances followed by gating system and finally design of the
feeder. Feeder design has been carried out using three different methods such as Caine's method, Modulus
method and Naval Research Laboratory (NRL) method and the highest value obtained by Caine's method is
taken for analysis. here, Feeder has been design in such a way that it should solidify last. A few important
calculation result are mentioned in the Table 1 as given below.
Table 1. Design parameters and their calculated values.
Sr.
No.
Designed Part Values
1. Mass of the casting (in Kg) 0.547
2. Pouring Time (in Seconds) 5.472
3. Diameter of Sprue at Top, Bottom and Sprue Length (in mm) 18, 15, 30
4. Sprue well: Diameter and Height (in mm) 30, 30
5. Runner dimensions: Width, Height and Length (in mm) 9, 18
6. Ingate dimensions: Width, Height and Length (in mm) 9, 18, 44
7. Feeder dimension based on Caine's method: Diameter of Feeder at Top,
Bottom & Height ( in mm)
50, 48, 50
8. Neck: Diameter and height (in mm) 22, 10
9. Pouring basin: Diameter at Top, Bottom and Height (in mm) 60, 40, 30
IV. SOLIDIFICATION SIMULATION USING AUTOCAST-X SOFTWARE
The software simulates the way casting engineers decide the casting process, parting line, cores, mold
box, feeders, gating system and mold layout, and analyzes each decision to suggest how the design could be
modified to improve quality as well as reduce tooling and manufacturing costs.
Solidification Simulation has been performed in AutoCAST-X environment according to the design
dimensions obtained for Pattern with allowances, gating system and feeder. Simulation study of castings aims
at identifying the hot spot locations, solidification time and thereby minimizing the shrinkage porosity etc.
Step wise procedure for method design, internal quality assessment and obtaining the yield of the casting using
AutoCAST-X software is outlined below:
The START module allows creating or opening a casting project, importing a part model, setting the
materials and process, selecting the mold size, and saving a layout. These inputs are required for all other
modules.
Fig. 2. imported part model of casting with mould shape and size
Imported a 3D part model created in any CAD software as standard .STL file as shown in Fig. 2. A
fitting mould will be automatically created and displayed.
The rectangular mould box was chosen and dimensions have been taken as 250×200×120 mm.
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The entire mould containing the casting was automatically sub-divided into cubic elements for
internal computations such as thickness, solidification and mould filling. The element size was
defined as 2.01 mm
Material selected was LM6 Grade Al alloy and sand casting was used as process.
The PART module is meant for computing the geometric and mass properties, analyzing the thickness
(including reference radiograph), and identifying cored holes if any. These results are needed for methods
design as well as for checking part-process compatibility. Part process compatibility has been checked using
the optimize function. Here three parameters are checked for part-process compatibility viz. part weight, part
size and minimum thickness as shown in Fig. 3.
Compatibility index = Σi importance of parameter i × compatibility of parameter i = 100%. A high
compatibility index indicates an optimal process-friendly part design. The index is zero if even one parameter
is incompatible (located in red zone).
Fig. 3. part-process compatibility evaluation
The MOLD module contains functions for orienting the part in mold, setting the parting line (flat or
stepped), designing cores (prints), deciding the number of cavities and their layout in mold. The mold size and
cavities can be optimized considering the ratio of cast metal to mold material. Part orientation as well as
parting plane placement is done in mold module as shown in Fig. 4.
Fig. 4. placement of horizontal parting plane
The parting line is created using the volumetric mesh elements. Parting direction is selected as
horizontal. Moldability index is 100% which is computed on the basis of metal to mold volume ratio, and
number of mold elements as shown in Fig. 5.
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Fig. 5. moldability index
The FEED module enables designing and optimizing the feeders (feeders) with or without the
feedaids to obtain the desired quality with high yield. Casting solidification is simulated and the results are
shown as cooling animation and feed metal paths. The feeder design can be automatically optimized, driven by
user constraints. Here, the last solidifying region of the casting has been identified as shown in Fig. 6. Green
colored dot in the Fig. 8. indicates the location of the feeder.
Fig. 6. hotspot indicating the last solidifying region
Now the feeder has been model according to the design dimensions and has been placed exactly on
the top of the hotspot as shown in Fig. 7. to allow feed metal transfer during volumetric contraction that
accompanies solidification shrinkage.
Fig. 7. partial shifted position of hotspot with the application of feeder
When insulating sleeve (exothermic) of 10mm thickness was incorporated and simulation was run.
The hotspot got completely shifted in the feeder as shown in Fig. 8.
Fig. 8. completely shifted position of hotspot with the application of feeder along with sleeve
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Two main results are produced in Solidification function:
Cooling animation: progressive solidification as shown in Fig. 9.
Feed metal paths: directional solidification as shown in Fig. 10.
Shrinkage porosity can be predicted by interpreting the above two results. This is expected in regions of high
temperature and low gradient. Ideally, feedpaths should end inside a feeder. Long and hot feedpaths
converging inside the casting imply a local hotspot that can result in a shrinkage porosity defect. Short and
cold feedpaths are usually harmless. Good (directional) feeding is characterized by:
Absence of isolated hot spots inside the casting
Feedpaths converging and leading inside the feeders
Fig. 9. cooling simulation of casting in 3D
Fig. 10. feed metal paths in 3d and in cross section
Shrinkage porosity was computed from the temperature and gradients using metal-specific process
characteristics. The shrinkage porosity is displayed as dots inside the casting red for macro and orange for
micro as shown in Fig.11. The simulation gives the value of macro porosity and micro porosity as 3.12 cm3.
Fig. 11. shrinkage porosity as seen in 3d, side view and front view (macro-red, micro-orange)
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The feeding design is evaluated (in terms of feedability index), and automatically optimized in this
function. A composite weighted feedability index is computed using the above criteria and their importance (1-
10 scale). The index is 100% if all criteria are in the green zone, and 0% if even one criterion is in the red
zone.
Fig. 12. feedability index
V. EXPERIMENTAL VALIDATION
After making wooden patterns as per design calculations for aluminium casting as shown in Fig. 13.
A mould box of size 250 x 200 x 120 was rammed using silica sand and the mould cavity was prepared in two
parts, Cope and Drag as shown in Fig. 14.
Fig. 13. wooden rigging system with pattern
Fig. 14.cope and drag with pattern embedded in mould box
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VI. RESULT
Casting trials were carried out without feeder, with feeder and feeder with exothermic sleeve. It can be
seen that casting without feeder directly shows shrinkage defect at the centre as shown in Fig.15., when the
feeder of 50mm diameter was placed no surface defects were present but when the component was machined
shrinkage porosity was found as shown in Fig. 16. but when same feeder was placed with an exothermic sleeve
of 10mm thickness no shrinkage related defects were found in the casting after machining as shown in Fig.17.
Fig. 15. casting without feeder shows defect
Fig. 16. casting with feeder of diameter 50mm shows defect after machining
Fig. 16. casting with feeder of diameter 50mm and sleeve thickness 10mm shows no defects after machining
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Fig. 17. section cut of casting with feeder of diameter 50mm and sleeve thickness 10mm shows no defects
VII. CONCLUSION
Solidification simulation has been performed in AutoCAST-X environment according to the design
dimensions obtained for pattern with allowances, gating system and feeder. Simulation study of castings has
provided the temperature contours which has helped in identifying the hot spot locations, solidification time
etc. Step wise procedure for method design, internal quality assessment and obtaining the yield of the casting
using AutoCAST-X software is outlined in this study.
When insulating sleeve(exothermic) of 10mm thickness was incorporated with the design dimensions
of the feeder and simulation was run. The hotspot has got completely shifted in the feeder.
Shrinkage porosity was computed from the temperature and gradients using metal-specific process
characteristics. The simulation gives the value of macro porosity and micro porosity as 3.12 cm3. This study
has shown that entire shrinkage porosity has been shifted in the feeder when it was designed properly.
Therefore more emphasise should be given on design phase of the casting by anticipating the probable
occurrence of the defects rather than controlling the process parameters. It save time to develop new casting,
wastage of material in carrying number of trials, to develop sound casting, energy and most important is
money.
Casting with feeder of diameter 48mm along with the sleeve of thickness 10mm has been validated by
performing actual trials in a foundry. Using sleeve as a feed aid helped in increasing casting yield.
REFERENCES
Journal Papers:
[1] Shamsuddin Sulaiman, Lim Ying Pio, Validation Of MAGMAsoft Simulation Of The Sand Casting Process, The
Institution of Engineers, Malaysia, September/December 2004, Vol. 65, No. 3/4, 55-64.
[2] Yeh-Liang Hsu, Chia-Chieh Yu, Computer Simulation Of Casting Process Of Aluminium Wheels – A Case Study,
J. Engineering Manufacture, 2006, Vol. 220, Part B, 203-211.
[3] Thoguluva Raghavan Vijayaram, Paolo Piccardo, Computers in Foundries, Metallurgical Science and Technology,
2012, Vol. 30-2, 28-38.
[4] P. Prabhakara Rao, G. Chakraverthi, A. C. S. Kumar, G. Srinivasa Rao, Modeling and Simulation of Solidification
in Alloy Steel Sand Castings, International Journal of Thermal Technologies, Dec. 2011, Vol.1, No.1, 110-116.
10. Minimization Of Shrinkage Porosity In A Sand Casting Process By Simulation In AutoCAST …..
| IJMER | ISSN: 2249–6645 | www.ijmer.com | Vol. 4 | Iss. 5| May. 2014 | 27|
[5] T. Ramu, M. L. S. Deva Kumar, B. K. C. Ganesh, Modeling, Simulation And Analysis In Manufacturing Of A
Flywheel Casting By S.G.Iron, International Journal of Materials and Biomaterials Applications, 2012; 2(4): 25-28.
[6] A. Kermanpur, Sh. Mahmoudi, A. Hajipour, Numerical Simulation Of Metal Flow And Solidification In The Multi-
Cavity Casting Moulds Of Automotive Components, Journal Of Materials Processing Technology, 2008, 1-7.
[7] T. Nandi, R. Behera, S. Kayal, A. Chanda, G.Sutradhar, Optimization Of Feeder Size Of Aluminium Alloy (LM6)
Castings By Using Conventional Method And Computer Simulation Technique, Nov. 2011, International Journal
Of Scientific & Engineering Research, Volume 2, Issue 11, 1-6.
[8] El Hassan E. M. Khalafalla, Hashim A. A. El Hashimi, Simulation Of Heat Flow In Aluminum Sand Casting,
Shendi University Journal, January 2010, Issue No. 8, 15-48.
[9] AutoCAST information and case studies, Advanced Reasoning Technologies Pvt. Ltd., http://www.adva-
reason.com.
Books:
[10] P. N. Rao, Manufacturing Technology (TATA Mc Graw-Hill Education, New Delhi, 2008).
[11] B. Ravi, Metal Casting: Computer Aided Design and Analysis (PHI Learning Pvt. Ltd.2011).