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.
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.
Computational study of a trailblazer multi reactor tundish (mrt) for improvin...eSAT Journals
Abstract Increasing the production efficiency of the continuous casting process requires casting longer sequences of ladles without stopping and restarting the caster. As the demand for wider ranges of steel products increases at the same time, the intermixing of dissimilar grades is becoming a problem of growing concern. When high grade dissimilar grade steel intermixed, huge amount of metal is lost from down gradation. With increased usage of steel for critical applications, the demand for cleaner steel has increased. Existing technologies have been improved and new technologies are being introduced all along the process route to minimize the size and quantity of inclusions. The bad effect of inclusion is it creates sliver in the hot rolled coil. To overcome the aforementioned problems a novel multi reactor tundish (MRT) technology has been developed which will decrease the intermixed amount during grade transition. Simultaneously it will increase the quality of steel by removing inclusion by increasing the plug flow and residence time in tundish. A computational study of the newly developed tundish has been done by using Fluent 6.3 computational fluid dynamics software and the results has been compared with two different type of normal tundish used in industry. Keywords: Tundish, Grade Transition, Inclusion, Yield
Minimization of Shrinkage Porosity in A Sand Casting Process By Simulation I...IJMER
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.
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
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.
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.
Computational study of a trailblazer multi reactor tundish (mrt) for improvin...eSAT Journals
Abstract Increasing the production efficiency of the continuous casting process requires casting longer sequences of ladles without stopping and restarting the caster. As the demand for wider ranges of steel products increases at the same time, the intermixing of dissimilar grades is becoming a problem of growing concern. When high grade dissimilar grade steel intermixed, huge amount of metal is lost from down gradation. With increased usage of steel for critical applications, the demand for cleaner steel has increased. Existing technologies have been improved and new technologies are being introduced all along the process route to minimize the size and quantity of inclusions. The bad effect of inclusion is it creates sliver in the hot rolled coil. To overcome the aforementioned problems a novel multi reactor tundish (MRT) technology has been developed which will decrease the intermixed amount during grade transition. Simultaneously it will increase the quality of steel by removing inclusion by increasing the plug flow and residence time in tundish. A computational study of the newly developed tundish has been done by using Fluent 6.3 computational fluid dynamics software and the results has been compared with two different type of normal tundish used in industry. Keywords: Tundish, Grade Transition, Inclusion, Yield
Minimization of Shrinkage Porosity in A Sand Casting Process By Simulation I...IJMER
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.
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
To Priority the Success Factors in the Design of Progressive Die by DFSS Meth...CrimsonPublishersAMMS
To Priority the Success Factors in the Design of Progressive Die by DFSS Methodology by Mozhgan Nozari, Amir Abbas Shojaie* and Sadigh Raissi in Aspects in Mining & Mineral Science
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.
Simulation of Stir Casting Process Using Computational Fluid DynamicsIJERA Editor
Stir casting process is one of the methods to produce Metal Matrix Composites (MMCs). But the Particle
Distribution of Non-Homogenous material is the greatest problem facing now days to produce MMCs. The
present simulations were conducted how the speed of the stirrer effects the Particle Distribution of Non-
Homogenous material. The Simulations were performed using Computational Fluid Dynamics. In this
experiment Copper is used as Semi Solid Metal (SSM) and Silicon-Carbide is used as solid metal. The
simulations were carried out by varying the stirrer speed 200 rpm and 400 rpm while keeping other parameters
constant such as Viscosity 4.4 mPa-s and Blade Angle 60 degrees. The results show that better distribution
obtained for the speed 400 rpm.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
To Priority the Success Factors in the Design of Progressive Die by DFSS Meth...CrimsonPublishersAMMS
To Priority the Success Factors in the Design of Progressive Die by DFSS Methodology by Mozhgan Nozari, Amir Abbas Shojaie* and Sadigh Raissi in Aspects in Mining & Mineral Science
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.
Simulation of Stir Casting Process Using Computational Fluid DynamicsIJERA Editor
Stir casting process is one of the methods to produce Metal Matrix Composites (MMCs). But the Particle
Distribution of Non-Homogenous material is the greatest problem facing now days to produce MMCs. The
present simulations were conducted how the speed of the stirrer effects the Particle Distribution of Non-
Homogenous material. The Simulations were performed using Computational Fluid Dynamics. In this
experiment Copper is used as Semi Solid Metal (SSM) and Silicon-Carbide is used as solid metal. The
simulations were carried out by varying the stirrer speed 200 rpm and 400 rpm while keeping other parameters
constant such as Viscosity 4.4 mPa-s and Blade Angle 60 degrees. The results show that better distribution
obtained for the speed 400 rpm.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
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.
Process optimization of pressure die casting to eliminate defect using cae so...eSAT Journals
Abstract
Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow
cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected
or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as
gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures
to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner
and overflow location and optimize the gating system and process parameters for best quality product and improved productivity.
Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the
casting. Mould filling and solidification process of a part was simulated using Z-cast software.
Key Words: Casting, HPDC, Z-cast, CAE Software, Simulation.
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
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
SPRING BACK PREDICTION OF SHEET METAL IN DEEP DRAWING PROCESSIAEME Publication
Spring back is one of the most significant phenomenon that affect the accurateness of the sheet metal parts. In order to obtain fixed tolerances for the formed parts it is highly recommended to use such process parameters/tool geometry that allow a considerably diminishing of the spring back amount. A Finite Element (FE) model is developed for the 2- D numerical simulation of sheet metal deep drawing process (Parametric Analysis) by using HYPERFORM with the appropriate material properties (anisotropic material) and simplifies boundary conditions
Warpage simulation of manhole cover using auto cast x softwareLaukik Raut
Designing an appropriate gating/risering system, some defects can be minimized such as cracks, distortion, shrinkage
porosity, warpage, sink, and shrinkage cavity by simulating the directional solidification using casting software. In this study, the
component from industry i.e. manhole cover is leading to premature failure of warpage or distortion. Hence, there is requirement
of optimizing the appropriate gating/risering system. In this paper, the actual gating/risering system is simulated to minimize the
warpage defect occurring in the industry while manufacturing. Hence, the simulation for optimizing better gating/risering system
is done by using AutoCAST-X software which is based on Vector Gradient Method (VGM) for defect minimization
Design of ‘plastic injection mold’ for an ‘air vent bezel’ through flow analy...eSAT Journals
Abstract Designer's of plastic injection Molds need to study from this point of view, the type of Mold to be designed, the physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels. Design can also be simplified by using standardized parts of the mold such as ejector pins. By eliminating the obstruction to smooth flow of plastic a good of quality component can be achieved. The effort of this thesis work is to find out the nuances in the Plastic Injection Mold Design while borrowing the inputs from the Flow Analysis (CAE) conducted for the 'Air vent bezel' to study the behavior of the Melt during flow. The Mold Design would incorporate suitable checking to ensure the best quality product in terms of `defect-free’ output. This thesis work consist methodology of plastic injection molding process, material requirement, how to overcome weld mark, shrinkage etc to satisfactorily assemble the component. Keywords: Draft angle, Shrinkage, CAE, weld mark
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.
The injection molding process itself is a complex mix of time, temperature and pressure
variables with a multitude of manufacturing defects that can occur without the right combination of
processing parameters and design components. Determining optimal initial process parameter
settings critically influences productivity, quality, and costs of production in the plastic injection
molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to
determine initial settings for a number of parameters, including melt temperature, injection pressure,
injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling
time which depend on the engineers’ experience and intuition to determine initial process parameter
settings. However, the trial-and-error process is costly and time consuming.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
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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
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.
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.
The Benefits and Techniques of Trenchless Pipe Repair.pdf
Paper id 28201443
1. International Journal of Research in Advent Technology, Vol.2, No.8, August 2014
E-ISSN: 2321-9637
82
Casting Simulation for Sand Casting of Flywheel
Naveen Hebsur1, Sunil Mangshetty2
1. Post graduate student, Department of Mechanical Engineering, PDA College of Engineering, Gulbarga,
Karnataka, India. Email:naveen_b6@yahoo.com.
2. Associate Professor, Department of Mechanical Engineering, PDA College of Engineering, Gulbarga,
Karnataka, India Email:mangshetty@rediffmail.com
Abstract- Sand casting technologies have now emerged as practical and commercial ways of manufacturing
high integrity near net shape castings. A variety of castings have found their way into general engineering
applications. Castings that serve these specific applications have to achieve the quality requirements of superior
mechanical properties and zero-porosity. To achieve these objectives within a limited time frame in a product
development process, CAD technologies combined with process simulation tools are increasingly used to
optimize form filling and solidification of the cast parts. This project describes the newly developed simulation
of flywheel component that was prototyped via sand casting route. Results of casting trials showed a high level
of confidence in the simulation tools.
Index Terms- Flywheel, Casting simulation, Greensand, Solidification, Fluid flow, Shrinkage.
1. INTRODUCTION
The formation of various casting defects is
directly related to fluid flow phenomena during the
mold filling stage and in the cast metal [1]. The rate of
solidification greatly affects the mechanical properties
such as strength, hardness, machinability etc [2]. One
of the critical elements that has to be considered for
producing a high quality sand casting product is the
gating system design and risering system design [3-4].
Any improper designing of gating system and risering
system results in cold shut and shrinkage porosities.
Therefore adequate care is necessary in designing
gating and risering systems for improved yield of
defect free castings
Casting simulation essentially replaces or
minimises shopfloor trials to achieve the desired
internal quality at the highest possible yield. A
number of casting simulation programs are available
today, such as ADSTEFAN, CastCAE, MAGMA,
Novacast, ProCAST, and SolidCAST. Most of them
use Finite Element Method to discretise the domain
and solve the heat transfer and/or fluid flow equations
[5]. The main inputs include the geometry of the
mould cavity (including the part cavity, feeders, and
gating channels), thermo-physical properties (density,
specific heat, and thermal conductivity of the cast
metal as well as the mould material, as a function of
temperature), boundary conditions (such as the metal-mould
heat transfer coefficient, for normal mould as
well as feed-aids including chills, insulation and
exothermic materials), and process parameters ((such
as pouring rate, time and temperature). The results of
solidification simulation include color-coded freezing
contours at different instants of time starting from
beginning to end of solidification. This provides a
much better insight into the phenomenon compared to
shop-floor trials (real moulds being opaque). The user
can verify if the location and size of feeders are
adequate, and carry out iterations of design
modification and simulation until satisfactory results
are obtained. Sometimes, it is not possible to achieve
the desired quality by changes to method (mainly
feeding and gating) alone. In such an event, it may
become necessary to modify the part design.
For example, the wall thickness of the part
can be increased (referred to as padding) at locations
that choke the flow of feed metal. Another typical
modification is adding or increasing taper to promote
directional solidification. These modifications
however, imply additional machining cost. If
feedability analysis is carried out at the product design
stage itself in a systematic manner, it can potentially
lead to superior product-process compatibility. This
implies foundry-friendly‟ castings, making it easier to
achieve the desired quality with high yield [6].
Shamasunder [7] discussed the steps involved,
possible sources of errors and care to be taken during
the casting process simulation. According to him the
designer needs to have full confidence in the casting
simulation tool. This can come only by experience
and usage of the tool to mimic effect of various
process parameters. With the advances in technology
and proper care in modeling, it is possible to simulate
the defects generated during casting before the casting
is practically produced. They presented different case
studies using ADSTEFAN software
The location and size of the feeders and
ingates is an important input for solidification
simulation. This decision requires considerable
methoding experience from the user. Further, the
engineer has to create or modify the solid model of
the feeder, attach it to the casting model using a CAD
program, and import it into the casting simulation
program for each iteration. These tasks require
computer skills. The accuracy of results (such as
2. International Journal of Research in Advent Technology, Vol.2, No.8, August 2014
E-ISSN: 2321-9637
83
solidification time and location of shrinkage defects)
is influenced by metallurgical models and availability
of temperature dependent material property database.
The simulation of intricate castings may involve more
time and cost than shop-floor trials, and any error in
program inputs implies further delay and expenses.
Casting simulation programs can be used by
foundry engineers for quality assurance and yield
optimization without shop-floor trials, as well as by
product engineers for analysing and optimising the
feedability of a casting during design phase itself. For
widespread application, the simulation programs
should require little domain experience, and they
should be fast, reliable, easy-to-use, and economical.
These goals can be achieved by automating some of
the tasks involved: identifying the location of a
feeder, calculating its minimum size, creating its solid
model, attaching the feeder model to the casting,
carrying out solidification simulation, predicting
quality and estimating the yield. The sand Casting
(Green Sand) molding process utilizes a cope ( top
half ) and drag ( bottom half ) flask of sand, ( usually
silica ), clay and water. When the water is added it
develops the bonding characteristics of the clay,
which binds the sand grains together. When applying
pressure to the mold material it can be compacted
around a pattern, which is either made of metal or
wood, to produce a mold having sufficient rigidity to
enable metal to be poured into it to produce a casting.
The process also uses coring to create cavities inside
the casting. After the casting is poured and has cooled
the core is removed. The material costs for the process
are low and the sand casting process is exceptionally
flexible.
In this work simulation is carried out for
manufacturing of STEEL flywheel and the results
were presented
.
2. CASTING SIMULATION
This includes mould filling, solidification,
grain structure, stresses and distortion. It requires
solid models of product and tooling (parting, cores,
mould layout, feeders, feedaids and gates),
temperature-dependent properties of part and mould
materials, and process parameters (pouring
temperature, rate, etc.). The simulation results can be
interpreted to predict casting defects such as
shrinkage porosity, hard spots, blowholes, cold shuts,
cracks and distortion. The inputs however, require
considerable expertise and may not be easily available
to product designers. One solution is to involve
tooling and foundry engineers in the product design
stage, and evolve the product, tooling and process
designs simultaneously, ensuring their mutual
compatibility with each other. This approach is
referred to as concurrent engineering.
3. Equationsmaterial and methodology
Flywheels are typically made of steel and
rotate on conventional bearings; these are generally
limited to a revolution rate of a few thousand RPM.
Chemical analysis of steel material is as shown below.
Element Wt %
C 0.25
Si 0.60
Mn 1.50
P 0.040
S 0.035
Cr 0.35
Ni 0.40
Mo 0.15
Cu 0.40
V 0.05
Table I: Chemical Properties of STEEL
Figure shows drawing of a typical flywheel. The
flywheel casting model with essential elements of the
gating system like In-gate, runner, sprue and risering
system were generated in CATIA V5 CAD modeling
software. Four ingates are provided at the first model
(fig 1), after the completion of first iteration the
shrinkage defect is occurred. In order to obtain sound
cast the model has to be modified in such a way that
two ingates are provided at the thicker section of inner
rib of flywheel and on which the risers are provided to
achieve the directional solidification (fig 2).
Fig: 1 Top & bottom view of f Flywheel
Fig: 2 Top & bottom view of f Flywheel
(modified model)
Simulation Process
ADSTEFAN is casting simulation software
developed by Hitachi Corporation Ltd, Japan. This
was used to simulate fluid flow and solidification of
3. International Journal of Research in Advent Technology, Vol.2, No.8, August 2014
E-ISSN: 2321-9637
Parameter Input condition
Velocity of fluid flow 19.8 cm/s
Fill time 38 sec
Critical solid fraction 0.8 (maximum 1)
Pouring type Gravity Pouring
1) Fluid flow
2) Solidification pattern
3)Shrinkage and
porosity
84
sand casting of flywheel. Casting simulation and
result analysis was done to predict the molten metal
solidification behavior inside the mold. The casting
component with gating system was imported in STL
(Stereo lithography) format to the ADSTEFAN
software and meshing of the model was done in the
pre-processor mesh generator module. The mesh size
of the casting was taken 5 and the structural boundary
conditions are automatically taken care by the
software.
Assignment of material properties, fluid flow and
solidification parameters: The meshed model was
taken into the precast environment of the software,
where the number of materials, type of mold used,
density of cast material, liquidus and solidus
temperatures of STEEL and other input parameters of
fluid flow and solidification conditions like pouring
time, pouring type, direction of gravity etc. were
assigned. Table & 5 show the material properties,
fluid flow & solidification parameters. After the
assignment of material properties and simulation
conditions, prediction of air entrapment, temperature
distribution and shrinkage porosity are carried out.
Casting simulation program provides output files in
the form of graphical images and video files which
are analyzed to predict defects after the successful
execution.
Table II: Input material properties and conditions
Parameter Type of
Mould
Conditions
Material Green Sand STEEL(IS
1030)
Density 1.5 gm/cm^3 7.6 gm/cm^3
Initial
Temperature
20°C 1580
Liquidus
temperature
-- 1505
Solidus
temperature
-- 1450
Table III: Input fluid flow and solidification
parameters
Output files
Riser type Open
4. RESULTS AND DISCUSSION
4.1 Fluid flow
Figure 3(a) (b) shows metal filling in mould cavity,
that ensure the smooth flow of Liquid metal and the
cold metal is not entering in the mould cavity. The
pouring temperature for steel is 1580°C to 1600°C.
The estimated pouring time for complete filling of
mould cavity is 38 seconds. From the iteration 1&2
we can easily predict that the cavity is filling
smoothly, uniformly without any turbulence and
temperature differences we can see. The Yellow color
highlights the temperature drop due to chill provided.
But this temperature drop is in safer side there are no
possibilities of cold metal or cold shut. In any of the
iteration there is no defect associated with fluid flow,
in casting component and gating system.
Fig: 3(a): Fluid flow in the casting component.
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E-ISSN: 2321-9637
85
Fig: 3(b): Fluid flow in the casting component.
4.2 Solidifaction
It is necessary to provide the directional solidification
in order to achieve the sound casting .The directional
solidification starts from thinnest section to thickest
section and which ends at riser. The actual
solidification of metal begins at liquidus temperature
of 1505°C. The solidification of metal ends at solidus
temperature 1450°C.
Defect affected zone
Fig: 4(a) Solidification of the casting component.
Fig: 4(b) Solidification of the casting component.
In figure 4(a) 1st iteration the inner rib of the flywheel
section is also chilled but the section thickness is
small at ingate area, so the hot spot is increased at
ingate area so isolation is formed in that section so
that isolation prone to defective area. Thus in orders
to eliminate these defective areas, the ingates are
provided at the thicker section of the inner rib of
flywheel component and simulation is carried out. In
2nd iteration only two ingates are provided on which
the risers are provided to achieve the directional
solidification and fig 4(b) shows the directional
solidification of the casting component.
4.3 Shrinkage Porosity
Figure 5 shows shrinkage porosity in the casting
component for first iteration of simulation. It is
observed that in first iteration gating system
simulation showed shrinkage porosities at four
different locations.
Fig: 5(a): Shrinkage porosity in the casting
component.
Fig: 5(b) Shrinkage porosity in the casting
component.
But in the 2nd iteration fig 5(b) these
shrinkage porosity are at the different locations of the
component are eliminated by providing ingates at the
proper location, and also the diameter of ingate are
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86
increased from 50 to 60mm and on which the risers
are provided. Thus shrinkage porosity decreased
significantly by 98%. These studies thus helped in
arriving at an optimum gating system.
5. CONCLUSION
In the present work a 3D component model was
developed using casting simulation software
ADSTEFAN to evaluate possible casting defects for
sand casting of flywheel. Notable conclusions from
this study are:
By adopting the pressurized gating system, the
fluid flow was smooth and air was expelled
without any entrapment inside the mould cavity.
Simulation showed that the molten metal was
able to fill the mould within the desired time.
Therefore fluid heat distribution was good and no
cold shut was observed.
In first iteration improper location of ingates led
to formation of shrinkage porosities where in the
second iteration only two ingates are located at
the thicker section of the inner rib of the
flywheel, on which risers are located in order to
achieve directional solidification.
The second iteration resulted in reducing the
shrinkages by 98% and the defect associated with the
cast is eliminated and the sound cast is achieved
Acknowledgments
The authors’ wishes to thank research paper review
committee, department of mechanical engineering.
Hod and Principal of PDA college of Engineering,
Gulbarga for their suggestions, encouragement and
support in undertaking the present work.
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