This document discusses a project report submitted by four students for their Bachelor of Technology degree in Mechanical Engineering. The report focuses on simulation and experimentation in casting feeder design. It begins with an acknowledgement section thanking those who provided guidance and support. The abstract provides a high-level overview, stating that the goal is to use solidification simulation and experimental pouring to optimize feeder design for an aluminum casting part to reduce defects during solidification. Key steps included simulating the part online, determining the feeder location and shape, and comparing experimental results to the simulation. It was concluded that properly selecting the feeder affects casting quality during solidification.
This document discusses the design of gating and risering systems for ductile iron castings. It begins with introductions to computer-aided design of gating and risering as well as the objectives of optimal design. The main body of the document then covers the following topics: risering system design principles and methods, including pressure control risering; gating system design principles and calculations for choke size and pouring time; and the algorithm used in the software for inputting data and calculating risering and gating dimensions based on casting properties. Design is checked to ensure adequate liquid feed is provided by the riser.
80 Ton Hot Metal Ladle Transfer Car is in our ready stock.
The details specification and its photo is attached herewith for your kind reference.
Purpose: intrashop transportation of Liquid Metal Ladle on straight horizontal sections of the track. The car will carry the ladle filled with liquid steel and convey the liquid steel.
Principle of operation:
Ladle Transfer Car, Flame Guard Trolleys along with stands to handle ladles up to 80 MT capacities complete with gear box, motors and electric panels.
A platform to keep electrode, guide equipment of ladle‚ slag pot etc. The car body is welded by steel plate, there are four wheels which is installed under main beam on both side, moving on trackway. A set of driving device is installed on rear of car body.
Technical Specification of Hot Metal Ladle Car
Total Load Carrying Capacity 80 Ton
Ladle Capacity 45 MT Liquid Metal + 25 MT Ladle with Refractory = 70 MT
Track Gauge ( Rail) 2700 mm
Speed of Ladle Car 0 to 25 Meter Per Minute
Ambient Temperature 60 Degree C
Wheel Base 3400 mm
No. of Bogies 01 No.
Drive system Electric Driven
The Ladle Transfer Car is ready for delivery. Please contact for more details.
remso2002@gmail.com or call at 0091 - 98- 1033 - 9183
This document provides an overview of aluminium, including its discovery, properties, production processes, applications, grades, and the aluminium market. It discusses that aluminium is the third most abundant element in the Earth's crust. The production process involves mining bauxite ore, refining alumina, and smelting alumina into aluminium. Major applications include transportation, packaging, and construction. China is the leading producer and consumer of aluminium globally. The document also compares aluminium to steel, noting advantages such as aluminium's lighter weight and better corrosion resistance. It outlines both the benefits and limitations of aluminium, as well as recent developments and future aspects of the aluminium industry.
Materials are tested to ensure quality, evaluate properties, prevent failure, and allow for informed material choices. There are two main types of material testing: mechanical tests which physically destroy samples to determine properties like strength; and non-destructive tests which inspect samples before use. Common tests include hardness testing using indenters, tensile testing to measure properties under load, and various non-destructive techniques like penetrant, magnetic particle, eddy current, ultrasonic, and radiographic testing to identify surface or internal flaws without damaging the sample.
This document provides an overview of manufacturing processes and gating systems for casting. It discusses the key elements of a gating system including the pouring basin, sprue, runner, gates, and riser. The objectives and factors affecting the performance of gating systems are outlined. Different types of gating systems like vertical, bottom, and horizontal are described. Formulas related to fluid flow and solidification time are also provided.
Design for Manufacturing Guidebook, Issue II Casting Design GuidelinesDFMPro
Though there are many kinds of casting processes with distinct design and manufacturing guidelines, we will initially look at the ones which are common to most casting processes. The rules covered in this issue are Fillet Radius, Uniform Wall Thickness, Mold Wall Thickness, Wall Thickness Variations, Undercuts and Draft Angle. Following these guidelines ensures that cast part is manufactured with desired dimensional accuracy, surface finish and quality.
To subscribe to Guidebook, please visit: http://dfmpro.geometricglobal.com/dfm-guidebook/
Product cost estimation in forging involves determining costs like material, labor, tools, and equipment based on the forging design and process. Key factors in cost estimation include determining the forging volume to select the proper equipment and estimate material losses from flash, scale, and sprues. A computer software has been created to aid in forging cost estimation.
This document discusses the design of gating and risering systems for ductile iron castings. It begins with introductions to computer-aided design of gating and risering as well as the objectives of optimal design. The main body of the document then covers the following topics: risering system design principles and methods, including pressure control risering; gating system design principles and calculations for choke size and pouring time; and the algorithm used in the software for inputting data and calculating risering and gating dimensions based on casting properties. Design is checked to ensure adequate liquid feed is provided by the riser.
80 Ton Hot Metal Ladle Transfer Car is in our ready stock.
The details specification and its photo is attached herewith for your kind reference.
Purpose: intrashop transportation of Liquid Metal Ladle on straight horizontal sections of the track. The car will carry the ladle filled with liquid steel and convey the liquid steel.
Principle of operation:
Ladle Transfer Car, Flame Guard Trolleys along with stands to handle ladles up to 80 MT capacities complete with gear box, motors and electric panels.
A platform to keep electrode, guide equipment of ladle‚ slag pot etc. The car body is welded by steel plate, there are four wheels which is installed under main beam on both side, moving on trackway. A set of driving device is installed on rear of car body.
Technical Specification of Hot Metal Ladle Car
Total Load Carrying Capacity 80 Ton
Ladle Capacity 45 MT Liquid Metal + 25 MT Ladle with Refractory = 70 MT
Track Gauge ( Rail) 2700 mm
Speed of Ladle Car 0 to 25 Meter Per Minute
Ambient Temperature 60 Degree C
Wheel Base 3400 mm
No. of Bogies 01 No.
Drive system Electric Driven
The Ladle Transfer Car is ready for delivery. Please contact for more details.
remso2002@gmail.com or call at 0091 - 98- 1033 - 9183
This document provides an overview of aluminium, including its discovery, properties, production processes, applications, grades, and the aluminium market. It discusses that aluminium is the third most abundant element in the Earth's crust. The production process involves mining bauxite ore, refining alumina, and smelting alumina into aluminium. Major applications include transportation, packaging, and construction. China is the leading producer and consumer of aluminium globally. The document also compares aluminium to steel, noting advantages such as aluminium's lighter weight and better corrosion resistance. It outlines both the benefits and limitations of aluminium, as well as recent developments and future aspects of the aluminium industry.
Materials are tested to ensure quality, evaluate properties, prevent failure, and allow for informed material choices. There are two main types of material testing: mechanical tests which physically destroy samples to determine properties like strength; and non-destructive tests which inspect samples before use. Common tests include hardness testing using indenters, tensile testing to measure properties under load, and various non-destructive techniques like penetrant, magnetic particle, eddy current, ultrasonic, and radiographic testing to identify surface or internal flaws without damaging the sample.
This document provides an overview of manufacturing processes and gating systems for casting. It discusses the key elements of a gating system including the pouring basin, sprue, runner, gates, and riser. The objectives and factors affecting the performance of gating systems are outlined. Different types of gating systems like vertical, bottom, and horizontal are described. Formulas related to fluid flow and solidification time are also provided.
Design for Manufacturing Guidebook, Issue II Casting Design GuidelinesDFMPro
Though there are many kinds of casting processes with distinct design and manufacturing guidelines, we will initially look at the ones which are common to most casting processes. The rules covered in this issue are Fillet Radius, Uniform Wall Thickness, Mold Wall Thickness, Wall Thickness Variations, Undercuts and Draft Angle. Following these guidelines ensures that cast part is manufactured with desired dimensional accuracy, surface finish and quality.
To subscribe to Guidebook, please visit: http://dfmpro.geometricglobal.com/dfm-guidebook/
Product cost estimation in forging involves determining costs like material, labor, tools, and equipment based on the forging design and process. Key factors in cost estimation include determining the forging volume to select the proper equipment and estimate material losses from flash, scale, and sprues. A computer software has been created to aid in forging cost estimation.
The document provides information about Indo Farm Equipment Limited, an ISO certified company located in Himachal Pradesh, India that manufactures tractors, cranes, engines, and generators. It discusses the company's founding, facilities, research and development activities, and organizational structure. It also describes the foundry plant's objectives, core making process, types of cores used, and the activities completed during a 10-day training session in the core shop, including making different types of cores by hand and machine.
This presentation covers all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR.
This presentation deals with the all the problems faced by this department midway through the process, and mainly focussing on "Bleeding Breakout" problem in TSCR shop.
Also an attempt is made to improve the so-called problem by suggesting certain measures at the end.
Just in time (jit), lean, and toyota production system (tps)Dr. Mahmoud Al-Naimi
This document discusses Just-in-Time (JIT) manufacturing, Lean manufacturing, and the Toyota Production System (TPS). It provides a history of manufacturing management approaches and describes Push and Pull systems. Key aspects of JIT include using kanban cards to signal production needs and leveling production schedules. Lean aims to eliminate waste using tools like total productive maintenance and 5S. TPS principles emphasize continuous improvement, problem solving, and respect for employees. The document explores the relationships between these systems and their goals of optimizing production flow.
Wire and bar drawing is a metalworking process that reduces the cross-sectional diameter of metal by pulling it through progressively smaller dies. It involves heating the metal, pointing one end, gripping it with pull-in dogs, and pulling it through dies made of materials like tungsten carbide or diamond. Wire drawing uses multiple dies in tandem and winding drums to continuously reduce the diameter, while bar drawing uses a single die. Proper lubrication is important to maintain surface finish and die life during the drawing process.
The document discusses various heat treatment processes. It defines heat treatment as operations involving heating and cooling of metals/alloys in their solid state to obtain desirable properties. It describes the stages of heat treatment as heating, soaking, and cooling. It then discusses various heat treatment processes like annealing, normalizing, hardening, and tempering in detail including their purposes, methods, and effects on material properties.
This document discusses various pattern allowances that must be accounted for when designing casting patterns. It describes shrinkage allowance, which accounts for the contraction of metals as they cool from liquid to solid. It also mentions machining allowance to allow for removal of surface imperfections during machining. Draft allowance tapers the pattern for easy removal from the mold. Distortion allowance accounts for uneven shrinking that can warp irregularly shaped castings. Finally, shake allowance enlarges the pattern to compensate for the mold cavity expanding slightly when the pattern is rapped to help removal.
Semi-solid metal casting (SSM) involves processing metals between their liquidus and solidus temperatures, when they are partially solidified. This allows for modifying the dendritic microstructure and improving mechanical properties compared to fully liquid casting. SSM techniques include thixocasting, which uses pre-cast semi-solid billets that are reheated and injected into dies, and rheocasting, where the liquid metal is sheared as it cools through the semi-solid range. SSM offers advantages over traditional casting like reduced porosity and finer microstructures, making it suitable for high-strength automotive and machine components.
This document provides information about the wire rod mill and bar mill at a steel plant, including:
- The wire rod mill has a capacity of 550,000 tons per year and can produce wire rod sizes from 5.5 to 22 mm. It is equipped with a 150 ton per hour walking beam reheat furnace.
- The bar mill has a capacity of 900,000 tons per year and can produce bar sizes from 8 to 50 mm. It is equipped with a 160 ton per hour walking beam reheat furnace.
- Both mills have multi-stand blocks for rolling, laying heads to form coils, and cooling beds. The document includes layout diagrams and details of the key equipment for each mill
The Rockwell hardness test measures the hardness of materials using indenters under specific loads. It is a quick, inexpensive, and non-destructive test that can be used to test finished parts without damaging them. The test uses a diamond or steel ball indenter that makes an impression under an initial minor load and then a deeper impression under a major load. The hardness number is read from a dial and indicates the material's resistance to plastic deformation. The test is commonly used for quality control and finding tensile strength.
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process...Ajjay Kumar Gupta
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills (Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes)
Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop. Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.
See more
https://goo.gl/y1STHt
https://goo.gl/S9g5Y4
https://goo.gl/n2H1QS
Contact us:
Niir Project Consultancy Services
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website :
http://www.niir.org
http://www.entrepreneurindia.co
Tags
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills, Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes, Best small and cottage scale industries, Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern small and cottage scale industries, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business
The document discusses various casting processes and defects. It describes the functions of gating systems which include providing uniform feed of molten metal to the mould cavity. It also explains the components of gating systems such as pouring basins, sprues, runners and gates. Risering systems are discussed as are common casting defects like shifts, warpage, swell and blowholes along with their causes and remedies. Shell moulding, die casting, and centrifugal casting processes are also summarized.
Just-in-time manufacturing is a production philosophy that aims to avoid waste by only producing items as they are needed. It evolved in Japan after WWII to reduce inventory costs and improve quality. Key principles include total quality management, pull-based production, close supplier relationships, and minimizing waste and inventory. Toyota is cited as pioneering JIT through practices like communicating demand to suppliers 20 days in advance and receiving over 2 million improvement proposals from employees in 1986. Benefits include lower costs and higher quality, while risks include lack of flexibility and reliance on suppliers.
O documento fornece uma introdução sobre o processo de lingotamento contínuo, abordando seus principais componentes e etapas. É dividido em 34 seções que descrevem tópicos como a história do lingotamento contínuo, física básica, composição química, tipos de máquinas, fluxo do processo, componentes como panelas e distribuidores, etapas como resfriamento e solidificação, além de aspectos como qualidade, defeitos e segurança.
The document discusses two common impact tests: the Charpy and Izod impact tests. The Charpy test involves dropping a pendulum onto a notched sample to measure the energy absorbed during fracture. It is used to evaluate toughness and notch sensitivity, especially of metals. The Izod test also measures energy absorbed during fracture but holds the sample in a cantilevered beam configuration rather than three-point bending. Both tests are useful for determining the strength and ductility of materials, especially their ability to withstand shocks and impacts in applications like forging, rubber products, and plastics.
Extrusion is a process where a block of metal is reduced in cross-section by forcing it to flow through a die under high pressure. There are different types of extrusion classified by direction (direct/indirect), temperature (hot/cold), and equipment (horizontal/vertical presses). Key equipment includes presses, dies, and tools. Dies must withstand high stresses and be designed for the desired shape. Process variables like temperature, extrusion ratio, and friction affect the required extrusion force. Hot extrusion near 50-75% of melting temperature is most common to reduce deformation resistance.
The document discusses the rolling process used in mechanical engineering. It begins with introductions and terminology for rolling. It then covers classifications of rolling mills like two high, three high, and four high mills. The types of rolling processes discussed include conventional, transverse, shaped, ring, powder, and thread rolling. Hot and cold rolling are also covered. Key aspects of the rolling process like roll bite condition and common rolling defects are defined. The document concludes with potential problems in rolling and sample multiple choice questions.
Indian Rail Steel- Pearlitic and Bainitic Rails and comparisionMukuldev Khunte
This study analyzes the effect of composition and microstructure on the properties of Indian rail steel. It summarizes the specifications and grades of Indian rail steel as well as the typical microstructures found, including pearlite and bainite. Head hardening is discussed as a process to refine pearlite, while bainitic rail steel is proposed as an alternative that offers higher hardness, strength and toughness than pearlitic rail steel. Track testing methods are presented for comparing wear performance of different rail compositions and microstructures. Thermite welding is also summarized as the primary joining technique used in rail production.
1) The project aimed to improve the direct pass ratio of castings produced by SUPPLIER for CUSTOMER from 0% to acceptable standards over 2 years.
2) Initial analyses found major casting defects and non-conformances due to issues like casting defects, poor mechanical properties, dimensions, and quality control processes.
3) Actions taken included establishing quality systems, control plans, process FMEAs, improving raw material combinations, training, and establishing testing standards.
4) Results showed significant improvement over 8 quarters from 17.65% to 93.36% direct pass ratio, with over 15,000 metric tons of acceptable castings produced after the project.
This document discusses planning and design of feeder bus services in Mumbai. It provides background on BEST, the public transit operator, and notes that feeder routes make up 52% of total routes. Feeder services are designed to transport passengers shorter distances, typically 4-6 km, to connect residential and commercial areas to trunk routes. Key considerations in planning feeder services include distance, travel time, infrastructure availability, frequency, and coordinating with trunk schedules. Challenges include lack of station infrastructure, long feeder distances, limited resources, and competition from other transit modes. Effective feeder services are important for integrating last mile connectivity within the overall transit system.
The document provides information about Indo Farm Equipment Limited, an ISO certified company located in Himachal Pradesh, India that manufactures tractors, cranes, engines, and generators. It discusses the company's founding, facilities, research and development activities, and organizational structure. It also describes the foundry plant's objectives, core making process, types of cores used, and the activities completed during a 10-day training session in the core shop, including making different types of cores by hand and machine.
This presentation covers all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR.
This presentation deals with the all the problems faced by this department midway through the process, and mainly focussing on "Bleeding Breakout" problem in TSCR shop.
Also an attempt is made to improve the so-called problem by suggesting certain measures at the end.
Just in time (jit), lean, and toyota production system (tps)Dr. Mahmoud Al-Naimi
This document discusses Just-in-Time (JIT) manufacturing, Lean manufacturing, and the Toyota Production System (TPS). It provides a history of manufacturing management approaches and describes Push and Pull systems. Key aspects of JIT include using kanban cards to signal production needs and leveling production schedules. Lean aims to eliminate waste using tools like total productive maintenance and 5S. TPS principles emphasize continuous improvement, problem solving, and respect for employees. The document explores the relationships between these systems and their goals of optimizing production flow.
Wire and bar drawing is a metalworking process that reduces the cross-sectional diameter of metal by pulling it through progressively smaller dies. It involves heating the metal, pointing one end, gripping it with pull-in dogs, and pulling it through dies made of materials like tungsten carbide or diamond. Wire drawing uses multiple dies in tandem and winding drums to continuously reduce the diameter, while bar drawing uses a single die. Proper lubrication is important to maintain surface finish and die life during the drawing process.
The document discusses various heat treatment processes. It defines heat treatment as operations involving heating and cooling of metals/alloys in their solid state to obtain desirable properties. It describes the stages of heat treatment as heating, soaking, and cooling. It then discusses various heat treatment processes like annealing, normalizing, hardening, and tempering in detail including their purposes, methods, and effects on material properties.
This document discusses various pattern allowances that must be accounted for when designing casting patterns. It describes shrinkage allowance, which accounts for the contraction of metals as they cool from liquid to solid. It also mentions machining allowance to allow for removal of surface imperfections during machining. Draft allowance tapers the pattern for easy removal from the mold. Distortion allowance accounts for uneven shrinking that can warp irregularly shaped castings. Finally, shake allowance enlarges the pattern to compensate for the mold cavity expanding slightly when the pattern is rapped to help removal.
Semi-solid metal casting (SSM) involves processing metals between their liquidus and solidus temperatures, when they are partially solidified. This allows for modifying the dendritic microstructure and improving mechanical properties compared to fully liquid casting. SSM techniques include thixocasting, which uses pre-cast semi-solid billets that are reheated and injected into dies, and rheocasting, where the liquid metal is sheared as it cools through the semi-solid range. SSM offers advantages over traditional casting like reduced porosity and finer microstructures, making it suitable for high-strength automotive and machine components.
This document provides information about the wire rod mill and bar mill at a steel plant, including:
- The wire rod mill has a capacity of 550,000 tons per year and can produce wire rod sizes from 5.5 to 22 mm. It is equipped with a 150 ton per hour walking beam reheat furnace.
- The bar mill has a capacity of 900,000 tons per year and can produce bar sizes from 8 to 50 mm. It is equipped with a 160 ton per hour walking beam reheat furnace.
- Both mills have multi-stand blocks for rolling, laying heads to form coils, and cooling beds. The document includes layout diagrams and details of the key equipment for each mill
The Rockwell hardness test measures the hardness of materials using indenters under specific loads. It is a quick, inexpensive, and non-destructive test that can be used to test finished parts without damaging them. The test uses a diamond or steel ball indenter that makes an impression under an initial minor load and then a deeper impression under a major load. The hardness number is read from a dial and indicates the material's resistance to plastic deformation. The test is commonly used for quality control and finding tensile strength.
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process...Ajjay Kumar Gupta
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills (Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes)
Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop. Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.
See more
https://goo.gl/y1STHt
https://goo.gl/S9g5Y4
https://goo.gl/n2H1QS
Contact us:
Niir Project Consultancy Services
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website :
http://www.niir.org
http://www.entrepreneurindia.co
Tags
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills, Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes, Best small and cottage scale industries, Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern small and cottage scale industries, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business
The document discusses various casting processes and defects. It describes the functions of gating systems which include providing uniform feed of molten metal to the mould cavity. It also explains the components of gating systems such as pouring basins, sprues, runners and gates. Risering systems are discussed as are common casting defects like shifts, warpage, swell and blowholes along with their causes and remedies. Shell moulding, die casting, and centrifugal casting processes are also summarized.
Just-in-time manufacturing is a production philosophy that aims to avoid waste by only producing items as they are needed. It evolved in Japan after WWII to reduce inventory costs and improve quality. Key principles include total quality management, pull-based production, close supplier relationships, and minimizing waste and inventory. Toyota is cited as pioneering JIT through practices like communicating demand to suppliers 20 days in advance and receiving over 2 million improvement proposals from employees in 1986. Benefits include lower costs and higher quality, while risks include lack of flexibility and reliance on suppliers.
O documento fornece uma introdução sobre o processo de lingotamento contínuo, abordando seus principais componentes e etapas. É dividido em 34 seções que descrevem tópicos como a história do lingotamento contínuo, física básica, composição química, tipos de máquinas, fluxo do processo, componentes como panelas e distribuidores, etapas como resfriamento e solidificação, além de aspectos como qualidade, defeitos e segurança.
The document discusses two common impact tests: the Charpy and Izod impact tests. The Charpy test involves dropping a pendulum onto a notched sample to measure the energy absorbed during fracture. It is used to evaluate toughness and notch sensitivity, especially of metals. The Izod test also measures energy absorbed during fracture but holds the sample in a cantilevered beam configuration rather than three-point bending. Both tests are useful for determining the strength and ductility of materials, especially their ability to withstand shocks and impacts in applications like forging, rubber products, and plastics.
Extrusion is a process where a block of metal is reduced in cross-section by forcing it to flow through a die under high pressure. There are different types of extrusion classified by direction (direct/indirect), temperature (hot/cold), and equipment (horizontal/vertical presses). Key equipment includes presses, dies, and tools. Dies must withstand high stresses and be designed for the desired shape. Process variables like temperature, extrusion ratio, and friction affect the required extrusion force. Hot extrusion near 50-75% of melting temperature is most common to reduce deformation resistance.
The document discusses the rolling process used in mechanical engineering. It begins with introductions and terminology for rolling. It then covers classifications of rolling mills like two high, three high, and four high mills. The types of rolling processes discussed include conventional, transverse, shaped, ring, powder, and thread rolling. Hot and cold rolling are also covered. Key aspects of the rolling process like roll bite condition and common rolling defects are defined. The document concludes with potential problems in rolling and sample multiple choice questions.
Indian Rail Steel- Pearlitic and Bainitic Rails and comparisionMukuldev Khunte
This study analyzes the effect of composition and microstructure on the properties of Indian rail steel. It summarizes the specifications and grades of Indian rail steel as well as the typical microstructures found, including pearlite and bainite. Head hardening is discussed as a process to refine pearlite, while bainitic rail steel is proposed as an alternative that offers higher hardness, strength and toughness than pearlitic rail steel. Track testing methods are presented for comparing wear performance of different rail compositions and microstructures. Thermite welding is also summarized as the primary joining technique used in rail production.
1) The project aimed to improve the direct pass ratio of castings produced by SUPPLIER for CUSTOMER from 0% to acceptable standards over 2 years.
2) Initial analyses found major casting defects and non-conformances due to issues like casting defects, poor mechanical properties, dimensions, and quality control processes.
3) Actions taken included establishing quality systems, control plans, process FMEAs, improving raw material combinations, training, and establishing testing standards.
4) Results showed significant improvement over 8 quarters from 17.65% to 93.36% direct pass ratio, with over 15,000 metric tons of acceptable castings produced after the project.
This document discusses planning and design of feeder bus services in Mumbai. It provides background on BEST, the public transit operator, and notes that feeder routes make up 52% of total routes. Feeder services are designed to transport passengers shorter distances, typically 4-6 km, to connect residential and commercial areas to trunk routes. Key considerations in planning feeder services include distance, travel time, infrastructure availability, frequency, and coordinating with trunk schedules. Challenges include lack of station infrastructure, long feeder distances, limited resources, and competition from other transit modes. Effective feeder services are important for integrating last mile connectivity within the overall transit system.
The document discusses the key components of a gating system - the pouring basin, sprue, runner, and gates. It explains that the gating system must provide defect-free castings by avoiding turbulence, filling the mould cavity completely before freezing, and controlling factors like pouring rate and metal temperature. An optimal gating system features tapered components to reduce velocity and erosion, and maintains the required thermal gradient. The document also covers guidelines for designing pouring basins, sprues, gates, runners as well as calculating pouring time and choke area.
This document presents guidelines for designing rigging systems (gating and risering) for different types of castings, including light alloys, ductile iron, and steel. For light alloys, the rigging system is designed to promote sequential solidification and minimize turbulence during filling to prevent oxide entrapment. Specific guidelines are provided for part orientation, locating the parting plane, sizing the sprue and runners, and using filters/screens. The document aims to compile common industry rules and methods engineer practices for different casting materials.
Six Sigma is a statistical methodology for improving process quality by reducing defects. It aims to reduce variation and improve customer satisfaction by focusing on key inputs that drive outputs. The Six Sigma methodology involves defining problems in terms of defects, measuring the current process performance, analyzing relationships between inputs and outputs, improving the process by experimenting with key inputs, and controlling the process to sustain improvements.
The document summarizes various casting processes including:
- Expendable and permanent molds made of materials like sand or metals
- Composite molds combining advantages of different materials
- Common casting methods like sand casting, shell molding, investment casting, and die casting where molten metal is poured or forced into molds
- Key factors like mold material, gating systems, solidification, and removing the casting after solidification.
This document discusses the planning and design of feeder bus services and short routes. It provides examples of different types of feeder routes in Mumbai, including circular routes in business districts, origin-destination based routes serving residential, employment, tourism areas, and peak period services. Case studies of specific feeder routes in Mumbai are presented, providing details on the route, length, frequency, fleet size, and occupancy. Challenges in operating feeder services discussed include lack of infrastructure at stations, long route lengths, limited resources, and competition from other transit options. The summary emphasizes that feeders are an important part of urban transit but require proper planning and integration with trunk services to effectively serve passenger needs.
This document provides information on dental casting procedures. It discusses the history of casting, steps in the casting process such as wax pattern fabrication and sprue attachment, types of investments and burnout procedures. The key points are: casting has been used since ancient times to produce jewelry and was introduced to dentistry by Taggart in 1907; the process involves fabricating a wax pattern, investing it, then burning out the wax and casting dental alloys into the mold.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms for those who already suffer from conditions like anxiety and depression.
This document provides instructions for humanely trapping feral cats through a process called Trap, Neuter, Return (TNR). TNR involves trapping feral cats, sterilizing and vaccinating them, and then returning them to their outdoor habitat. The instructions detail how to prepare traps by lining them with newspaper and baiting them with smelly foods. It also explains how to cover the traps to prevent the cats from seeing outside once trapped and how to safely transport trapped cats to a veterinarian for sterilization before being released. The goal of TNR is to humanely control the feral cat population through sterilization while allowing the cats to remain in their outdoor homes.
The document provides an overview of the software architecture for a data entry system. It includes sections on use case view, logical view, and process view. The use case view describes key use cases such as building institutional identifiers, gathering author emails, and resolving problematic emails. The logical view outlines significant design packages including data models, view models, and controllers. The process view decomposes system processes like institutional identifiers and author email gathering into lightweight sub-processes.
This document is an artist resume for David Hahn, a composer and guitarist. It summarizes his educational background, including a Ph.D. in Historical Musicology from Stanford University and degrees in music from New England Conservatory and Brown University. It also lists his commissions, premiere performances, teaching experience, honors/awards, and professional affiliations.
Debora Sanders-Smiley has over 30 years of experience in call center management, operations management, staff management, and project management. She has held leadership roles such as Director of Financial Claims Call Center Operations and Director of Call Center Operations. Currently, she works as an independent consultant providing services such as project management, staff training and development, and human resources management. She has consulted for both private businesses and educational institutions.
This curriculum vitae summarizes the educational background and professional experience of David Hahn. He holds a Ph.D. in Historical Musicology from Stanford University and has over 30 years of experience as a professional musician, composer, and music instructor. His areas of expertise include guitar, lute, mandolin, early music, composition, electronic music, and music technology. He has received several awards and grants for his compositions which have been performed internationally.
Carrie Lindholm's final project focuses on integrating technology like blogs, photo galleries, and communication logs into the Pre-Kindergarten classroom. The project also evaluates new technologies being used in the classroom, including five iPads used during free time and centers, and educational apps like Teach Me Toddler that track individual student progress. Lindholm aims to help parents understand and support their children's use of technology in learning.
The document summarizes a student project that used casting simulation software to analyze and optimize the design of a simple valve component cast using sand casting and investment casting processes. The initial sand casting design was simulated and found to be prone to porosity in several regions. Risers were added to the design and a second simulation showed the porosity was isolated to the risers. An investment casting simulation of the same component found negligible porosity isolated to risers. The sand casting process was found to be more economical for small scale production while investment casting was better suited for batch production of higher quality parts.
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.
Design & Fabrication of a low cost spin coaterSaurabh Pandey
Spin Coating is basically a procedure which is used to deposit uniform thin films to any flat surface of work piece. Usually a small amount of coating material is applied on the centre of the work piece’s surface when the disk is spinning at very low speed. Here in this process we are using the basic principle of centrifugal force. This is applied due to the spinning of Disk.
IRJET-Gating and Feeder Design of Aluminium Alloy (6061 T6) Casting for Circu...IRJET Journal
This document describes the design of a gating system and feeders for an aluminum alloy casting of a circular component. It outlines the calculations to determine the dimensions of the sprue, runners, ingates, and feeders. The goal is to produce a defect-free casting through proper gating system and feeder design. Key steps included calculating the pouring rate and time, choke area, sprue dimensions, runner and ingate areas using a 1:4:4 gating ratio, and feeder size and shape based on the casting volume. The design aims to minimize turbulence during filling and properly compensate for solidification shrinkage.
This document provides an overview of a study conducted on the casting methodology and defects at Peekay Steels Pvt. Ltd. It discusses the following key points:
1. The objectives of the study were to study Peekay's industrial casting process in depth and examine casting defects using radiography testing to minimize defects.
2. The methodology involved 5 phases: background research, studying Peekay's process, examining their gate valve production, making prototypes, and testing defects.
3. Peekay's casting process involves several departments coordinating complex patterns, molds, melting, heat treatment and quality control. Their no-bake molding process uses chemical binders for strength and dimensional tolerances.
This document provides a guide for tunnel lining design. It begins with an introduction that outlines the guide's structure and objectives. The guide is then divided into 10 chapters that cover topics such as project definition, geotechnical characterization, design considerations, theoretical analysis methods, instrumentation and monitoring, and quality management. Case histories are also provided. The overall aim is to provide practical recommendations and guidance to help engineers properly design tunnel linings.
This document describes the design and development of an adjustable plastic pylon for lower limb prosthetics. It begins with an introduction to prosthetics and the role of the pylon. It then discusses the objectives and methodology for designing an adjustable plastic pylon to replace existing fixed-height metal pylons. The document reviews existing pylon designs, materials selection including plastics like POM and PBT, structural analysis using ANSYS, and process simulation using Moldflow. It then presents the proposed adjustable plastic pylon design which was analyzed, optimized, and prototyped using stereolithography for design confirmation.
This document provides information about a manufacturing processes laboratory course, including:
- The schedule lists 13 sessions over 14 weeks for demonstrations, exercises, an exam, and student projects.
- General instructions are provided on safety, submitting reports, dress code, cleaning work areas, and more.
- Recommended reading materials are listed to refer to for answering question bank questions.
- An introduction is given on the different parts of the course, including demonstrations, exercises, an exam, and student projects focused on casting, metal forming, and other manufacturing processes.
This document describes the design and fabrication of a wear test specimen die for metal matrix composite materials. It provides details of the project, including the equipment used for wear testing, die specifications designed using NX8 software, test specimen dimensions based on ASTM standards, the material selection and properties of oil hardened non-shrinking steel chosen for the die material, and the manufacturing processes employed to produce the die including casting, machining operations and electric discharge machining. The goal of the project is to produce a die that can be used to test the wear behavior of metal matrix composites.
Manufacturing technology process introduction and foundary44LEETSaurovsharma
The document discusses manufacturing processes and metal casting. It covers the basic steps in the casting process, which include pattern making, molding and core making, melting and casting, fettling, and testing and inspection. It also discusses pattern materials, which can include wood, metals, plaster, plastic compounds, and waxes. The key factors in selecting a pattern material are the design, number of castings needed, quality and shape of the casting, type of molding process and material, possibility of design changes, and repetition of castings.
Investigating the causes and remedies for porosity defects in the casting pro...bijejournal
The casting process is a crucial manufacturing method utilized in numerous sectors to create intricate components
and forms. However, there are a number of underlying causes of casting flaws that can result in subpar quality,
higher costs, and decreased productivity. This review seeks to give a general overview of casting process flaws,
their causes, and possible fixes. The evaluation will go over the various possible flaws, including porosity,
shrinkage, and surface abnormalities, as well as their underlying causes, which include design, material, and
process characteristics. Furthermore, the review will focus on various remedial measures that can be taken to
overcome these defects and improve casting quality, such as changes in design, material selection, and process
optimization. This review will be useful for researchers and practitioners in the casting industry who are interested in
improving their understanding of casting defects and developing effective remedial measures to enhance product
quality and efficiency.
1) Shell mold casting is a metal casting process where a mold is made from a thin-walled shell created by applying a sand-resin mixture around a pattern. This allows for higher production rates and more complex geometries compared to sand casting.
2) The process involves creating a reusable metal pattern, heating it, and applying a sand-resin mixture to form a shell mold around the pattern. The shells are then cured, filled with molten metal, and broken to remove the casting.
3) Shell mold casting provides advantages like high dimensional accuracy, automation potential, fewer gas defects, and lower labor costs compared to sand casting. It is often used for small to medium parts requiring precision.
Manufacturing Technology of Materials in Engineeringssuser0cd0f1
The document discusses the casting process and provides details on:
1. The basic steps of sand casting including making molds, pouring molten metal, and allowing solidification.
2. Key terms used in casting like flasks, patterns, and risers.
3. How to make a simple sand mold by preparing the drag and cope halves of the mold, making gates and vents.
4. The purpose and design of gating systems, risers, and pouring basins to effectively fill the mold and compensate for shrinkage.
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
This document analyzes particle fracture in hypereutectic aluminum-silicon alloys through Vickers microindentation tests. Results for second-phase silicon particles were compared to monolithic silicon. Subsurface damage mechanisms beneath indented silicon particles were studied to determine the crack morphologies causing particle fracture and the role of indentation-induced phase transformations. Cross-sectional FIB and TEM revealed a semi-circular plastic core and subsurface lateral crack pattern below residual indents, in addition to a localized amorphous silicon zone below the plastic core at crack edges.
Development and Progress of V-process in Chinazhang jianman
(1) The document discusses the development and progress of V-process casting in China. It began being studied in 1974 and has grown significantly, with over 500 firms now using the technique.
(2) The key aspects of V-process casting are that it uses vacuum instead of binders in the sand mold. This allows for high dimensional accuracy and surface quality in castings.
(3) The document outlines the history and increasing applications of V-process casting in China. It is now used for castings in various industries such as machinery, rail, automotive, and more. The technology and equipment for V-process casting in China has also advanced greatly.
Design and Analysis of fluid flow in AISI 1008 Steel reduction gear boxIRJET Journal
This document summarizes a research paper that analyzes fluid flow in an AISI 1008 steel reduction gearbox using computer simulation. The researchers redesigned the gearbox model in CATIA and analyzed it using casting simulation software to optimize the design and minimize defects from shrinkage, hotspots, and solidification time. They simulated the original design and a modified design with changes to the riser and gating system dimensions. The simulations aimed to improve yield by reducing porosity and defects in the casting.
Project report - mechanical - internal pipe painting machinefaheem m m
This document is a project report on the design of an internal pipe painting machine. It includes sections on introduction, literature survey, objectives, methodology, design development including concept modeling, material selection and final design. The design development section includes 3D modeling and drawings of the various components of the machine like the spray head, air motor, arbor extension, collar, material tube, carrier collar, holder strap, carriage, wheel assembly etc. It also includes the manufacturing process details like metal cutting, lathe machining, sawing, welding, drilling and inspection process. The final section includes the advantages, applications and conclusion of the internal pipe painting robot.
This document provides an overview of the fundamentals of open pit mine planning and design. It is the first volume of a multi-volume work on open pit mine planning and design by authors William Hustrulid, Mark Kuchta, and R. Martin. The document covers topics such as mine planning, estimating revenues and costs, orebody description methods, geometrical considerations, pit limits determination, production planning, and reporting of mineral resources and reserves.
Similar to simulation and experimentation in feeder design_secure (20)
simulation and experimentation in feeder design_secure
1.
SIMULATION AND EXPERIMENTATION IN
CASTING FEEDER DESIGN
A PROJECT REPORT
Submitted by
PATEL ARTH G.
POONAWALA TAHA Y.
SANGHANI DARSHAK V.
SUKHADIA DHAVAL V.
in partial fulfillment for the award of the degree
of
BACHELOR OF TECHNOLOGY
in
MECHANICALENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
FACULTY OF TECHNOLOGY
DHARMSINH DESAI UNIVERSITY, NADIAD
DEC 2014
2.
3. i
ACKNOWLEDGEMENT
This report would not have been possible without the kind support and help of many
individuals. We would like to extend our sincere thanks to all of them. We thank Prof. R. V.
SOLANKI, Prof. N. A. VORA and Mr. H. T. PATEL for their kind co-operation with
enough encouragement towards the completion of this report.
We are highly indebted to Dr. MAYUR SUTARIA (CSPIT, Changa) for his guidance as
well as for providing necessary information regarding this work and his support in completing
it. We thank Prof. RAKESH BAROT (BVM, V V Nagar) for guiding us at the right moment.
We would like to express our gratitude and thanks to industry person Mr. RAJESHKUMAR
TOSHNIWAL (M/s. UTSAV METALS, NADIAD) for using his foundry to carry out the
experiment. We specially thank Mr. BALKRISHNAN for providing a helping hand at various
stages.
We are also grateful to the lab technicians of our departmental workshop for giving a helping
hand at all times without any discontent.
We would like to express our gratitude towards our parents for giving us moral support to work
hard. Our heartfelt thanks and appreciations to our classmates who supported us in taking up
this work and people who have willingly helped us out with their abilities.
4. ii
ABSTRACT
In metal casting, defect free castings which require least finishing operations has been the
primary goal since the inception of technology. There is always a compromise between the cost
involved in the production of cast component and the quality required. Besides, it is always
desired that the yield of casting is maximized against the volume of feeder/riser accommodated
to meet the solidification shrinkage requirement.
The shrinkage porosity defect is one of the most common solidification defects of sand casting
process. It occurs in the thickest sections of casting which is possessing lasting freezing point.
The practical approach of design of feeder has high factor of safety and due to that oversized
feeders have normally been designed and tested on shop floor. This consumes lot of time and
resources. Thus, there is a need for computer aided optimal feeder design coupled with
solidification simulation so as to reduce the no. of the shop-floor trials and obtain enhanced
yield and high quality, in minimal possible time.
The initial design is the aluminium casting part (without feeder) which is simulated online in
Efoundry to detect the location of hotspot. Then a feeder is designed on the following steps:
determination of the feeder-neck connection point on the casting surface, initial feeder design
and feeder shape optimization using Efoundry till the hotspot is obtained in the feeder itself.
The same part is then experimentally poured and verified with cut-section. It is observed from
actual pouring that shrinkage cavity had shifted towards the feeder whereas it remained at the
center of the junction in the non-feeder part. It is concluded at the end that the selection of
proper feeder affects the quality of casting during solidification.
5. TABLE OFCONTENTS
NO. TITLE PAGE
Acknowledgement i
Abstract ii
Table of Contents iii
List of Figures v
List of Tables vi
Nomenclature vii
1. Introduction to Metal Casting 1
1.1. Founding or Casting 1
1.2. History of Casting 1
1.3. Casting Process Steps 2
1.4. Applications 2
2. Quality of Castings 3
2.1. Need of Quality 3
2.2. Defects in casting 4
2.3. Significance of Defects 5
2.4. Methods of Improvement 6
2.5. Use of Computers 6
3. Literature Survey 7
4. Research Problem Definition 9
4.1. Motivation 9
4.2. Goal 10
4.3. Research Objectives 10
4.4. Research Approach 10
4.5. Scope 10
5. Solidification and Shrinkage 11
5.1. Mechanism of Solidification in Pure Metals 11
5.2. Shrinkage 11
5.2.1. Liquid Contraction 11
5.2.2. Solid Contraction 12
5.2.3. Solidification Contraction 12
5.3. Solidification Simulation 12
6. 6. Pouring and Feeding Castings 13
6.1. Gating System 13
6.1.1. Elements of Gating System 13
6.1.2. Gating System Design 14
6.2. Feeders 16
6.2.1. Principles of Feeding 16
6.2.2. Types of Feeders 17
6.2.3. Feeder Design 18
6.3. Casting Yield 20
7. Feeder Design Simulation and Experimentation 21
7.1. Junction Definition 21
7.2. Pattern, Feeder and Mould Design 22
7.2.1. Pattern Allowances and Design 22
7.2.2. Feeder Design using Caine’s Method 22
7.2.3. Sprue, Runner and Gate Design 24
7.2.4. Moulding Sand & Mould Box 26
7.3. Simulation in Efoundry 26
7.4. Experimentation in Foundry 30
8. Experimental Results and Discussion 32
9. Conclusion 36
Future Work 37
References 38
7. v
LIST OFFIGURES
Fig.No. Description Page No.
1.1 The casting process 1
2.1 Defects in casting 4
4.1 Foundry Defect Spectrum 8
5.1 Development of columnar crystals 11
5.2 Solidification contraction regimes in liquid, freezing and solid range 11
6.1 Elements of Gating System 13
6.2 Solidification of a cube casting 16
6.3 Classification of Casting Feeders 17
6.4 Top & Side Feeder Shapes 17
6.5 Progressive Directional Solidification 19
7.1(a) Orthographic View - Selected ‘X’ Junction geometry 21
7.1(b) Isometric View - Selected ‘X’ Junction geometry 21
7.2 Geometry with top feeder 24
7.3 Mould Box Section 25
7.4 Drag pattern 25
7.5 Cope pattern with riser and sprue 26
7.6(a) Efoundry Simulation Step - 1 27
7.6(b) Efoundry Simulation Step - 2 27
7.6(c) Efoundry Simulation Step - 3 28
7.6(d) Efoundry Simulation Step - 4 28
7.7(a) ‘X’ junction solidification simulation 29
7.7(b) ‘X’ junction solidification simulation with feeder of dia D = 62 mm 29
7.7(c) ‘X’ junction solidification simulation with feeder of dia D = 64 mm 29
7.8(a) Sand Preparation 30
7.8(b) Facing Sand application for Drag 30
7.8(c) Rammed Drag 30
7.8(d) Mould cavity in Drag 30
7.8(e) Cope preparation by placing feeder & sprue 31
7.8(f) Venting in the cope 31
7.8(g) Final Drag & Cope Assembly 31
7.8(h) Metal Pouring 31
7.8(i) Final Cast Product 31
8.1 Cast job without feeder 32
8.2 Cut Plane Section in the job without feeder 32
8.3 Cast job with feeder 33
8.4 Cut Plane Section in the job with open top feeder 34
8.5 Top Feeder and its Cut Plane Section 34
8. vi
LIST OFTABLES
Table
No.
Description
Page
No.
5.1 Solidification shrinkage for major cast metals 12
7.1 Physical Properties of Geometry 21
7.2 Pattern Allowances 22
7.3 Moulding Sand Properties and Composition 26
7.4 Pouring Condition Parameters and Alloy Composition 31
9. vii
NOMENCLATURE
M Modulus
C Efficiency factor for gating system
H Height
SA Surface area
H Potential head
P Pressure
v Liquid velocity
V Volume
W Specific weight
g Gravitational acceleration
Q Rate of flow
A Area of cross section
W Weight of casting
T Pouring time
Mass density of the molten metal
Solidification time
∈ Feeding efficiency
Shrinkage factor
D Diameter of feeder
X Freezing ratio
Y Yield
Length of neck
Diameter neck
Sprue base diameter
Sprue top diameter
Sprue top area
Gate area
Choke area
k Mould constant
Temperature of solid
Subscripts
c casting
f feeder
N neck
10. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 1
Chapter 1
INTRODUCTION TO METAL CASTING
1.1 Founding or Casting
The process in which the metal is first liquefied by properly heating it in a suitable furnace and
pouring the molten metal in a previously prepared mould cavity where it is allowed to solidify
is termed as metal casting. Subsequently, the product is taken out of the mould cavity, trimmed
and cleaned to the required shape. Casting is one of the oldest manufacturing process, and even
today it is the first step in manufacturing of most products.
1.2 History of Casting
Casting is one of the oldest manufacturing methods which dates back to 4000 B.C. In early
years, the axe heads of copper were cast in open stone moulds. During that period gold, silver,
copper, bronze, etc. were widely cast. Some decorated bronze castings could be seen in the
European churches. Also, earlier castings of cast iron were those of cannon shots and grave
slabs. Later, the first foundry center came into existence in the days of Shang dynasty (1766-
1122 BC) in China. The Greeks and Romans revealed the use of decorated ornaments and metal
bells. Moreover, the process of casting was known to certain families only and was considered
as an art and craft.
In 1540, Biringuccio wrote on Metal Founding which was further adopted and reworked by
Reaumur who studied the various factors influencing the production of white, malleable and
gray irons. A no. of foundries came into existence after the British Industrial Revolution.
During the mid-20th
century newer techniques came into existence, the phenomenon of casting
[Fig. 1.1] – The casting process
11. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 2
could be understood better and more no. of young men took interest to develop the subject.
Today, no. of methods have been discovered and patented to obtain the best casting for different
materials e.g. lost wax casting process, centrifugal casting, die casting, etc. Besides, computer
simulation has also been put to effort to analyze and optimize the various factors influencing
the process.
1.3 Casting Process Steps
Make the Pattern out of wood, metal or plastic
In case of Sand Casting, select, test and prepare the necessary sand mixtures for mould and
core making.
With the help of patterns prepare the Mould (a container having a cavity of the shape to be
cast) and necessary Cores (body of sand which is employed to produce cavity in casting).
Melt the metal/alloy to be cast.
Pour the molten metal/alloy into the mould and remove the casting from the mould after
the metal solidifies.
Clean & Finish the casting.
Test & Inspect the casting.
Remove the Defects, if any.
Relieve the casting stresses by Heat Treatment.
Again inspect the casting.
The casting is ready for shipping.
1.4 Applications
The growing demand of high precision castings and of intricate designs at lower costs has
helped considerably in the development of Foundry industry. Hardly there is any product
which does not have one or more cast components. Few such applications are:
1. Automobile parts
2. Machine tool structures
3. Turbine vanes
4. Power generators
5. Railway crossings
6. Pump filter and valves
7. Aircraft jet engine blades
8. Communication, Construction and Atomic Energy applications
12. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 3
Chapter 2
QUALITY OF CASTINGS
2.1 Need of Quality
Casting quality is one of the keys to survival in foundry industry. High quality castings depend
on the ability of a casting producer to test and inspect all the raw materials. The ability to
discriminate between imperfections greater than the allowable severity due to various causes
plays an important role in reducing the rejection rate of castings. It is essential that enough
focus is laid down to implement a proper cast product in single pour so as to minimize the
amount of metal loss which is lost as vapourized metal oxide during the melting process. Major
points of concern during the design of a cast product are:
1. Appropriate allowances on the pattern and mould cavity
As molten metal cools it shrinks depending on its properties i.e. thermal expansion
coefficient and hence proper shrinkage allowance should be added
The cast product obtained does not have good surface finish generally in sand casting
method and hence proper machining allowance should be added
Both these factors add to the oversizing of the cavity than the actual job which adds to
the cost of casting
2. Fettling process
The pathway through which molten metal enters the mould cavity comprises of
elements like runners and gates
Riser or feeders are placed to accommodate the metal requirement during solidification
These elements have to be removed of the cast product after solidification and is sent
to the furnace for melting
This process induces large losses in terms of loss of metal and the defects caused in
the cast product due to improper design of runner, gates and risers
3. Properties of sand and other raw materials
When the molten metal cools in the mould cavity heat transfer takes place through
the surfaces of mould cavity
If these surfaces do not provide adequate amount of heat transfer chances are there
that the cavity might blow off or hot spots remain in the core of the component or any
other type of defect is obtained
Due to chemical reactions or variation in the solubility of molten metal at different
temperature and phase, gases are evolved and need to be vented out properly
13. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 4
Considering the above points and various other affecting factors, the casting need to be
optimized for compromise against a defect free part and the metal loss.
2.2 Defects in Casting
Defects arise in castings due to faulty casting design, faulty method of casting and faulty
workmanship. The casting design defects include faulty a) pattern equipment, b) flask
equipment and rigging, c) gating and risering and d) sand and cores compositions. A defect
may arise from a single clearly defined cause or more generally may be due to a combination
of causes interacting with each other. Common defects in castings as observed are shown in
the fig and they are defined as follows:
1. Blow – a fairly large, well-rounded cavity produced by the gases which displace the molten
metal at the cope surface of the casting due to inadequate venting
2. Scar – a shallow blow, usually found on a flat casting surface
3. Blister – a scar covered by thin layers of metal
4. Gas Holes – entrapped gas bubbles having nearly spherical shape, and occur when an
excessive amount of gases is dissolved in the liquid metal
[Fig.2.1] – Defects in casting
14. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 5
5. Pin Holes – tiny blow holes which occur either at or just below the casting surface and are
found generally in large castings with uniform distribution over the entire casting surface
6. Porosity – very small holes uniformly dispersed throughout a casting due to decrease in gas
solubility during solidification
7. Drop – an irregularly shaped projection on the cope surface of the casting caused by
dropping of sand from cope or other overhanging projections into the mould
8. Inclusion – non-metallic particles in the metal matrix
9. Dross – lighter impurities appearing on the top surface of the casting
10. Dirt – small angular holes obtained when sand particles dropping out of the cope get
embedded on the top surface of the casting and are removed
11. Wash – a low projection on the drag surface of a casting commencing near the gate, caused
by erosion of sand due to the high velocity of jet of liquid metal in bottom gating
12. Buckle – a long, fairly shallow, broad, V-shaped depression occurring in the surface of a
flat casting of a high temperature metal because of the bulging of mould face
13. Scab – a rough, thin layer of metal, protruding above the casting surface, on top of a thin
layer of sand resulting due to separation of sand at that place and the flow of metal through
that path between sand and mould
14. Rat Tail – a long, shallow, angular depression found in thin casting
15. Penetration – in a soft and porous mould surface, the molten metal may flow between the
sand particles up to a distance, into the mould causing rough, porous projections
16. Swell – found on vertical surfaces of casting if the moulding sand is deformed by the
hydrostatic pressure caused by high moisture content in sand
17. Misrun – liquid metal due to insufficient superheat freezes before reaching the farthest
point of the mould cavity
18. Cold shut – insufficient mixing of metal at the intersection of two streams
19. Hot tear – a crack developed due to high residual stresses
20. Shrinkage cavity – improper riser design leads to quick solidification of the metal inside
the mould causing internal or external voids as the shrinkage is not compensated
21. Shift – misalignment between two halves of a mould or of core
2.3 Significance of Defects
Under working conditions, some defects in the casting may be inherent and their significance
can only be established in relation to the function of the casting. Behaviour under service
stresses and environment in most cases is the over-riding consideration and its appearance as
well. Besides, the defect affects its mechanical properties and surface condition.
15. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 6
2.4 Methods of Improvement
A no. of variables like raw material composition variations, furnace operation variation,
variations in pouring of liquid metal, variations in mould, cooling conditions, etc. are to be
manipulated simultaneously to obtain a sound casting with good surface finish. The foundry
which was once considered as an ‘Art’ is now the ‘Science’ of foundry.
Improved strength in a casting can be obtained by manipulating the internal structures of the
casting which in turn involves controlling the rate of heat transfer through the mould and
cooling of casting and modifying additions to influence solidification of casting. Good surface
finish can be obtained by minimizing mould-metal interface reactions and by controlling
evolution of gases during solidification stage. Dimensional accuracy of castings are influenced
by fluidity of melts, shrinkage due to liquid-solid phase transformation, mould materials and
methods of mould making and the casting method employed.
2.5 Use of Computers
The computer represents the most significant and universally applicable development in
business and commercial activity. In particular, there is an overlap between the cost estimating
activity and the determination of the method of production, encompassing both pattern layout
and gating and feeding system designs. Earlier computer applications in foundry industry saw
application in the field of optimizing the weight and cost estimation.
It is possible at present to select the correct choice of mould making, core making and the
casting process if the input data based on design considerations are available by Value
Engineering and Value Analysis. Value Engineering co-relates function with cost and Value
Analysis concerns the selection of correct manufacturing process. Value Analysis finds out the
manner in which the casting part will be stressed in service whereas Value Engineering
suggests the casting procedure. For improving strength and quality of castings Multiple Linear
Regression analysis data, Optimisation and Simulation methods are generally applied.
Regression analysis plots experimental data to find co-relations between the various variables.
Gating and Feeding system design for the given casting are simulated in various softwares like
Novocast (Dewtec Computer Systems Ltd.,UK), ProCAST, Flow-3D, Star-Cast, MAGMA and
SOLIDCast with FLOWCast and OPTICast. These programs perform coupled simulation of
mould filling and solidification for a given casting design with complete feeders, runners and
gating. The widespread availability of powerful, yet low cost computers has opened the
possibility of creating, analyzing and optimizing virtual castings so that quality components
can be produced in minimum no. of shop-floor trials.
16. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 7
Chapter 3
LITERATURE SURVEY
1. Heine et al. in 1968 gave the principle of directional solidification which meets the feed
path requirement. It states that, “If the feeder can be placed on the highest modulus section
of the casting, with progressively thinner (lower modulus) sections extending away, then
the condition of progressive solidification towards the feeder can be met.”
2. Jong et al. in 1991, described that the casting can be separated into different feeding
sections by dividing into simpler shapes at different sections called feeding unit. A feeding
unit is a group of casting sections in which modulus decreases progressively from the
highest modulus section to the lowest modulus section. Each feeding unit requires a
separate feeder.
3. Wu et al. in 1992, gave the critical modulus gradient which is needed to be maintained in
all feeding units to ensure proper feed direction.
4. Chvorinov in 1996, gave one of the earliest geometric based optimization efforts which
was proposed on the modulus method and related it directly to solidification time of a
casting.
5. Wlodawer used Chvorinov’s rule to design the feeders in such a way that the modulus
(M) of the feeder is greater than that of the casting and must increase by 10% from
the casting across the ingate to the feeder for ensuring adequate feeding. He proposed a
relationship between casting, neck and feeder modulus as
: : 1 ∶ 1.1 ∶ 1.2
6. Ravi & Srinivasan in 1996, proposed the Vector Element Method (VEM) which
determines the feed path and location of hot spot inside the casting, using the direction
of the largest thermal gradient at any point inside a casting to move along a path which
leads to a hot spot (a local maxima of temperature with gradients tending to zero).
7. Campbell in 2004 laid out the feeding rules which gives an idea for feeder size
calculation and its location.
8. Jacob, Roschen et. al. in 2004 presented a novel approach to the problem of feeder design
by augmenting genetic algorithms with CAD to optimize the feeder dimensions. Genetic
algorithms based on empirical rules were used as an optimization tool. A 3-dimensional
CAD model of casting is modeled using CAD software. The casting is further divided into
feeding sections and their volume, surface area were calculated. For each feeding section
17. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 8
feeder is designed by using parallel search in the domain of all possible solution and thus a
population of probable solutions are prepared. A fitness function is defined on the basis of
population of solutions, and is used in maximization of casting yield.
They also showed that the required modulus of the feeder is given by the relation:
∗
The value of multiplication factor mainly depends on the cast metal (for steel is 1.3, ductile
iron is 1.15, grey iron is 1.0) and it was proposed by Ravi et al., in 1997.
9. B. Ravi et al. presented various works related to casting simulation in the previous years
some of which are:
a. Location of feeder and its shape selection
b. Framework of feeder design and optimization in order to maximize the yield and
productivity against high rejection rate
c. Feeder neck proportions and a taper section so that modulus of the neck increases
as it moves away from the casting
10. D Joshi, B Ravi in 2009, presented the classification and simulation based design of 3D
junctions in casting wherein VEM was employed to predict the extent of shrinkage porosity
defect and it was validated experiments. A benchmark part with 3D junction was also
presented to show how simulation can be used to predict and prevent the defect by
modifying the junction design.
11. Elizabeth Jacob, Dundesh S. Chiniwar, Savithri S, Manoj M and Roschen Sasikumar
in 2013, carried out simulation based feeder design for metal castings wherein the casting
part alone is simulated and the solidification profile is used to identify the hotspot and
design the feeder. The feeder was further improved and verified with simulation in “Virtual
Feed” software which was then simulated in AUTOCAST software (3D Foundry Tech) to
check for hotspots.
12. E‐Foundry, developed at IIT-B is a part of the NKN (National Knowledge Network)
mission to connect knowledge providers and seekers through a high bandwidth network.
Users can freely access the teaching content developed in IIT‐B, to update their knowledge
in casting design and simulation. It also offers online simulation lab, which accepts a 3D
CAD model and generates solidification images. It can be accessed through the following
link : http://efoundry.iitb.ac.in/
18. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 9
Chapter 4
RESEARCH PROBLEM DEFINITION
4.1 Motivation
Manufacturing of defect-free components at low cost and high productivity is important for the
casting industry today. The major challenges that the industry faces are large number of shop
floor trials, high rate of rejection and low casting yield. These can be overcome by adopting
solidification simulation technology. A typical foundry defect spectrum is shown below which
indicates that shrinkage holds a majority in defect related issues.
Solidification of the molten metal after being poured is an important phase in the casting
process which greatly affects the casting quality (produces shrinkage defects) and its yield. To
compensate for the shrinkage during the phase change, the required liquid is obtained from the
adjacent liquid regions. The last freezing regions are the most probable locations of shrinkage
cavities, which need feeders appended at suitable location on the casting. The total volume of
the feeder should be minimized to improve casting yield and productivity. The design and
optimization of the feeder requires intensive human interaction and numerous trial and error
iterations. The assistance of simulation tools for determining the optimal shapes, sizes and
locations of the feeders while compromising against the quality and cost constraints are
difficult to achieve.
Several optimization methods have been integrated into commercially available software like
AUTOCAST, CAST PRO, etc. which yield an easy design of the entire cast component
including feeders, gates, etc. The ready availability of computer technology, to automate the
casting design and optimization process makes both economic and engineering sense.
[Fig.4.1] – Foundry Defect Spectrum
19. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 10
4.2 Goal
Goal of the research is “design of feeder for a selected cross junction widely found in various
casting products which has the root cause of creating a shrinkage cavity and to validate this
design by experimentation.”
4.3 Research Objectives
• Study the solidification simulation of the junction
• Design of the feeder
• Re-simulate the junction along with its feeder
• Experimentation of the design by pouring molten metal
4.4 Research Approach
Research approach is divided into following steps to achieve the objective:
• Literature study on Solidification, Shrinkage and Feeder Design using Efoundry’s video
lectures by Dr.B.Ravi
• Selection of metal (Aluminium), moulding method (sand moulding) and junction
parameters and simulating it in Efoundry for locating the hotspot
• Feeder design using Caine’s method, locating it on the selected junction and simulating it
in Efoundry to check for ‘No hotspots at the junction’
• Design of pattern and making the appropriate mould cavity for metal pouring in a junction
with and without feeder
• Verifying the results by observing the cut-plane section at the hotspot region in both the
jobs
4.5 Scope
Scope for this project is being limited to design of feeder and validating the design by actual
pouring for Aluminium (ADC 12 grade) in Green Sand Casting. This project is focused on the
junction with single hot spot in the geometry and which has been addressed by a single feeder.
20. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 11
Chapter 5
SOLIDIFICATION AND SHRINKAGE
5.1 Mechanism of Solidification in Pure Metals
Liquids need to be cooled below their freezing points before the solidification begins. This is
because energy is required to create surfaces for new crystals. The degree of super cooling
necessary is reduced by the presence of other surfaces which serve as the initial nuclei for the
crystal growth. When a liquid metal is
poured into a mould, initially the temperature
everywhere is . The mould face itself acts
as the nucleus for crystal growth, and if the
conductivity of the mould is high, randomly-
oriented small crystals grow near the mould
face. Subsequently, a temperature gradient
results within the casting, as indicated in fig.
for and . As the solidification progresses
gradually inwards, long columnar crystals,
with their axes perpendicular to the mould
face, grow. This orientation of crystal growth
is desirable from the point of view of strength
of casting.
5.2 Shrinkage
The molten metal in the mold cavity occupies
considerably more volume than the solidified
castings that are eventually produced. This is for
the compensation of volumetric contraction which
metal exhibits. There are three quite different
contractions to be dealt with when cooling from
the liquid state to room temperature, as shown in
the fig. 4. They are:
5.2.1. Liquid Contraction: This contraction
occurs while metal is cooling in liquid state, since
liquid grows in density as it cools. This type of
contraction in the liquid state does not pose a significant problem because most of the
[Fig.5.1] – Development of columnar crystals
[Fig.5.2] – Solidification contraction regimes
in liquid, freezing and solid range
(adapted from Campbell, 2003)
21. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 12
superheat of a melt is usually lost during or quickly after pouring. It is compensated by
pouring more molten metal.
5.2.2. Solid Contraction: The solid contraction occurs after the casting has solidified and
as it cools from the solidification temperature to room temperature. To ensure that the
dimensions of the castings are correct, the pattern used to produce the given casting is
usually made slightly larger than the casting dimension.
5.2.3. Solidification Contraction: Contraction during solidification occurs at the freezing
point, since density of the solid is greater than density of liquid. This type of contraction is
the root cause of solidification related defects which in turn causes shrinkage porosity or
cavity. To compensate solidification contraction extra metal needs to be fed to the solidifying
casting. This extra metal is provided by separate reservoir of metal called as feeder, since
its action is to feed the metal to casting.
5.3 Solidification Simulation
The solidification process involves the transformation of the hot liquid metal to solid and
then subsequent cooling of the solid to the room temperature. Solidification of molten
metal after being poured into a mold cavity is an important phase in the casting process
which greatly affects the product quality and yield. During the past two decades, computer
modeling of solidification simulation has been widely used in foundry with an aim to:
Predict the pattern of solidification, including shrinkage cavities and associated defect
predictions for various ferrous metals like steel, grey iron, ductile iron and nonferrous
metals like aluminium, copper, etc. as well as in precious metals like gold, silver,etc.
Simulate solidification in various orientation of casting, with various metal-process
combinations, so that optimal position can be selected.
Such simulation can be obtained in Efoundry, developed by a team of faculty members under
Dr.B.Ravi’s supervision at IIT-Bombay. It gives an approximate visualization of the
solidification in a given casting. This can be used to know how efficient a designed feeder will
work so as to reduce the number of experimental trials.
Metal
Melting Point
(C)
Liquid density
(kg/m3
)
Solid density
(kg/m3
)
Shrinkage
(%)
Aluminium 660 2385 2700 7.1
Copper 1084 8000 8960 5.3
Cast Iron 1370 6900 7100 3.0
Cast Steel 1640 7015 7870 5.0
[Table 5.1] – Solidification shrinkage for major cast metals
22. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 13
Chapter 6
POURING AND FEEDING CASTINGS
6.1 Gating System
Gating system refers to all those elements, which are connected with the flow of molten metal
from the ladle to the mould cavity. The aim of the gating system is to provide a defect-free
casting. The various elements that are connected with a gating system are discussed as follows.
6.1.1 Elements of Gating system
1. Pouring Basin
The molten metal is not directly poured into the mould cavity because it may cause mould
erosion. The molten metal is poured into a pouring basin, which acts as a reservoir from which
it moves smoothly into the sprue. The main function of a pouring basin is to reduce the
momentum of the liquid flowing into the mould by settling first into it.
2. Sprue
Sprue is the channel through which the molten metal is brought into the parting plane where it
enters the runners and gates to ultimately reach the mould cavity. Sprue is tapered to gradually
reduce the cross section as it moves away from the top of the cope so that velocity of flow at
the bottom is increased.
3. Sprue Base Well
This is a reservoir for metal at the bottom of the sprue to reduce the momentum of the molten
metal. The molten metal as it moves down the sprue gains in velocity, some of which is lost in
the sprue base well by which the mould erosion is reduced. This molten metal then changes
direction and flows into the runners in a more uniform way.
[Fig.6.1] – Elements of Gating System
7. Riser
23. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 14
4. Runner
It is generally located in the horizontal plane (parting plane), which connects the sprue to its
in-gates, thus allowing the metal enter the mould cavity.
5. Runner Extension
The runner is extended a little further after it encounters the in-gate so as to trap the slag in the
molten metal.
6. Gate or In-gate
These are the openings through which the molten metal enters the mould cavity. The shape and
the cross section of the in-gate should be such that it can readily be broken off after casting
solidification and also that it allows the metal to enter quietly into the mould cavity. Depending
on the application, various types of gates used in the casting design are: Top Gate, Bottom
Gate, Parting Gate and Step Gate.
7. Riser
Most of the foundry alloys shrink during solidification. As a result of this volumetric shrinkage
during solidification, voids are likely to form in the casting unless additional molten metal is
fed into these places which are termed hot spots since they remain hot till end. Hence, a
reservoir of molten metal is to be maintained from which the metal can flow into the casting
when the need arises. These reservoirs are called risers.
6.1.2 Gating System Design
The liquid metal that runs through the various channels in the mould obeys the Bernoulli’s
theorem which states that the total energy head remains constant at any section. The same stated
in the equation form ignoring frictional losses is
2
where, = potential head, m; = pressure, Pa; = liquid velocity, m/s; = specific weight
of liquid, N/m3
; = gravitational acceleration
Though quantitatively Bernoulli’s theorem may not be applied, it helps to understand
qualitatively, the metal flow in the sand mould.
Another law of fluid mechanics, which is useful in understanding the gating behavior is the
law of continuity which says that the volume of metal flowing at any section in the mould is
constant. The same in the equation form can be
24. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 15
where, = rate of flow, m3
/s; = area of cross section, m2
; = velocity of metal flow, m/s
It is preferred that sprues are tapered in order to reduce the aspiration of air due to the increased
velocity as the metal flows down the sprue. This conclusion was drawn by applying the above
equation of continuity along with the Bernoulli’s equation.
The three parameters which are used in the gating design are:
1. Pouring Time
The time for complete filling of a mould termed as pouring time, is a very important criterion
for design. Too long a pouring time requires a higher pouring temperature and too less a
pouring time means turbulent flow in the mould which makes the casting defect prone. There
is thus an optimum pouring time for any given casting.
The pouring time depends on the casting materials, complexity of the casting, section thickness
and casting size. For nonferrous materials, a longer pouring time would be beneficial since they
lose heat slowly and also tend to form dross if metal is poured too quickly. Generally, a thumb
rule used for calculation is given below, though various empirical relations are available.
√
where, pouring time,s; W = weight of casting
2. Choke Area
After calculating the optimum pouring time, it is required to establish the main control area
which meters the metal flow into the mould cavity so that the mould is completely filled within
the calculated pouring time. This controlling area is called choke area.
The choke area can be calculated using Bernoulli’s equation as
2
where = choke area, mm3
; W = casting mass, kg; = pouring time,s; = mass density of
the molten metal, kg/mm3
; = effective metal head (sprue height), mm; = effeciency
factor which is a function of the gating system used
The effective sprue height , of a mould depends on the casting dimensions and type of gating
used.
3. Gating Ratios
The gating ratio refers to the proportion of the cross sectional area between the sprue, runner
and in-gates and is generally denoted as sprue area : runner area : in-gate area.
25. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 16
A typical gating ratio recommended or used in practice is 1:2:1. Besides, it is a general practice
to cut the runner in the cope and the in-gate in the drag to help in the trapping of slag. Moreover,
the in-gates are made wider compared to the depth, up to a ratio of 4. This facilitates in the
severing of gating from the casting after solidification. Small casting may be designed with a
single in-gate, however, large or complex casting require multiple in-gates to completely fill
all the sections of the castings effectively.
6.2 Feeders
In most cases, the terms risers and feeders are used interchangeably. Riser is something which
is open to the atmosphere and the metal can been seen rising in the mould cavity. Feeder on
the other hand has the job of feeding liquid metal to the hotspot. It can be blind or open.
Therefore, all risers are feeder but all feeders are not risers.
6.2.1 Principles of Feeding
The function of a feeder/riser is to feed the casting during solidification so that no shrinkage
cavities are formed. The requirement of the feeder depends to a great extent upon the type of
metal poured and the complexity of the casting. Various materials have different volumetric
shrinkages of which grey CI sometimes has a negative shrinkage and some metals such as
aluminium and steel have high volumetric contraction and hence, risering is required.
Shrinkage cavity development can be understood from the following example. Fig 6.2(a)
shows a cube which is completely filled with liquid metal. As time progresses, the metal starts
losing heat through all sides and as a result starts freezing from all sides, equally trapping the
liquid metal inside as shown in fig 6.2(b). Further solidification of the metal causes a
subsequent volumetric shrinkage which leads to metal concentration and thus, causes void
formation. The solidification when complete, finally results in the shrinkage cavity as shown
in fig 6.2(d).
[Fig.6.2] – Solidification of cube casting
(a) (b) (c) (d)
26. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 17
The reason for the formation of the void in the above cube casting is that the liquid metal in
the center which solidifies in the end is not fed during the solidification, hence the liquid
shrinkage occurred ends up as a void. Such isolated spots, which remain hot till the end are
called ‘hot spots’. A casting designer has to reduce all this hot spots so that no shrinkage
cavities occur.
In this connection, the term directional solidification is normally used in the casting
terminology. It means that the solidification of the metal should start at the remotest point of
the casting from the feeder. Since the cooling is achieved by the removal of heat from all
surfaces which are exposed to the atmosphere or sand, cooling normally starts from the point
which is thinnest or is exposed over a larger surface area.
6.2.2 Types of Feeder
A general classification of feeders is shown below:
An open feeder is exposed to the atmoshpere whereas a blind feeder is closed at its top. The
top feeders are placed above the hot spot, whereas the side feeders are placed at the side of
the hot spot, usually at the parting line. The various shapes used for such feeders are shown in
fig. 6.4.
[Fig.6.3] – Classification of Casting Feeders
[Fig.6.4] – Top & Side Feeder Shapes
27. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 18
6.2.3 Feeder Design
Solidification of the casting occurs by losing heat from the surface and the amount of the heat
is given by the volume of the casting. Hence, the cooling characteristics of a casting can be
represented by the surface-area-to-volume ratio. Since the riser is similar to the casting in its
solidification behavior, the riser characteristics can also be specified by the ratio of its surface
area to volume.
If this ratio of the casting is higher, then it is expected to cool faster. Chvorinov has shown that
the solidification time of a casting is proportional to the square of the volume-to-surface area
of the casting. The constant of proportionality called the Mould Constant depends on the
pouring temperature, casting and the mould thermal characteristics.
2
where = solidification time, s; = volume of casting; = surface area; = mould
constant; = modulus of casting
Some general rules have been laid out for feeder design on the basis of the above
characteristics. They are discussed as below:
1. The modulus criterion or heat transfer criterion is that the feeder must solidify at the
same time as, or later than the casting. This is satisfied by ensuring that the feeder has a modulus
(volume to surface area ratio) that is sufficiently larger than the casting by a multiplication
factor. The required modulus of the feeder is given by
∗
Multiplication factor for steel is 1.3, ductile iron is 1.15, grey iron is 1.0.
2. The casting can be separated into different feeding sections by dividing into simpler
shapes at different sections called feeding unit. A feeding unit is a group of casting sections in
which modulus decreases progressively from the highest modulus section to the lowest
modulus section. Each feeding unit is isolated from other feeding units by the low modulus
regions in between them.
3. The volume criterion states that the feeder must contain sufficient molten metal to meet
the volume contraction requirements of the casting. This is satisfied by ensuring that the feeder
has sufficient volume to feed all the shrinkage. The feeder volume should be at least equal to
the minimum volume given by
∗
28. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 19
where, feeding efficiency is volume fraction of the feeder that is actually available for
feeding and = shrinkage factor
4. The feed path criterion states that there should be positive feed paths to flow from the
liquid to all parts of the casting it is supposed to feed. In order to meet the feed path requirement,
the principle of directional solidification is followed. If the feeder can be placed on the highest
modulus section of the casting, with progressively thinner (lower modulus) sections extending
away, then the condition of progressive solidification towards the feeder can be met. The
number and position of feeders should be designed based on this criterion.
5. On the basis of the feeder location and type of connectivity, various parameters related
to feeder shape are considered. Taller feeders are used for steel castings (e.g. for cylindrical
feeders H/D = 2, where H and D are height and diameter of cylinder, respectively), which
exhibit shrinkage pipe, whereas in iron and aluminum castings, H/D value can be about 1.5.
6. Efficiency of feeder is characterized by modulus i.e. volume/heat transfer area. By
selecting different feeder shape we can have different efficiency. Casting yield is depending on
volume of feeder so it is necessary to reduce the volume of feeder. For small castings,
cylindrical feeders are widely used. For larger castings, cylindrical feeders with spherical
bottom (side location) or spherical top (top position, blind type) are widely used.
7. After determining the feeder dimension, shape and connection point, feeder neck is
assigned. Feeder neck is an important parameter, designed in a way to ensure decreasing
modulus towards the casting. This is done to ensure that the neck should solidify after the
casting hotspot and to maintain the flow of liquid metal from the feeder to casting hotspot.
∗
The multiplication factor is 1.2 to 1.5 depending on the cast metal.
8. The shape of the feeder-neck depends on the feeder shape, feeder position and the
connected portion of the casting. The most widely used neck shapes are cylindrical (for top
cylindrical feeders) and rectangular (mainly for side feeders). The neck may also be tapered
down towards the casting, thereby gradually reducing the modulus towards the casting.
9. Above all, casting yield should be maximized by using optimization techniques.
[Fig.6.5] – Progressive Directional Solidification
29. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 20
6.3 Casting yield
All the metals that is used while pouring is not finally ending up as a casting. On completion
of the casting process, the gating system used is removed from the solidified casting and
remitted to be used again as raw material. Hence, the casting yield is the actual volume of
casting required to the volume of metal poured into the mould cavity.
∗ 100
The higher the casting yield, the higher is the economics of the foundry practice. It is therefore
desirable to give consideration to the maximizing the casting yield, at the design stage itself.
Generally, those materials which shrink heavily have lower casting yield. Also, massive, and
simple shapes have higher casting yields compared to small and complex parts.
30. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 21
Chapter 7
FEEDER DESIGN SIMULATION AND
EXPERIMENTATION
7.1 Junction Definition
‘X’ junction is widely encountered in parts where 4 streams of metal get together. They are the
main regions where hotspot formation is always possible and hence leads to shrinkage cavity.
One such section of size 100 x 100 mm is selected. The part dimensions, isometric view,
orthographic view and physical properties of the job are shown below:
Physical Properties
Material ADC 12 (Al-Si : 83.4% - 11.2%)
Vcasting 233376 mm3
S.A.casting 29756 mm2
ρcasting 2823 kg/m3
mcasting 0.658 kg
Mcasting 7.842 mm
[Fig.7.1] – Selected ‘X’ Junction geometry
7.1(a) Orthographic view
7.1(b) Isometric view [Table 7.1] – Physical Properties of geometry
31. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 22
7.2 Pattern, Feeder and Mould Design
7.2.1 Pattern Allowances and Design
A wooden pattern for the selected junction is prepared. The various allowances so provided
on the pattern for Aluminium casting are as follows:
Allowance type Theoretical Allowance Actual Allowance Provided
Shrinkage 0.015 mm per mm 0.01 mm per mm
Draft ½-2 ⁰ ½-2 ⁰
7.2.2 Feeder Design Using Caine’s Method
Keeping in mind the various laid out rules for feeder design in the previous section and using
Caine’s method, the design of feeder is as follows:
The ‘freezing ratio’, X, of a mould is defined as the ratio of cooling characteristics of the casting
to the riser.
In order to be able to feed the casting, the riser should solidify last and hence its freezing ratio
should be greater than unity. It may be argued that the sphere has the lowest surface-area-to-
volume ratio and hence that it should be used as a riser. But in a sphere, the hottest metal being
at the centre, it is difficult to use it for feeding the casting. The next best is the cylindrical type
which is most commonly used for its ease in moulding.
Based on the Chvorinov’s rule, Caine developed a relationship empirically for the freezing
ratio as follows:
where
;
, and are constants whose values for Aluminium are 0.10, 0.06 and 1.08 respectively.
Design steps:
Volume of casting = 233376 mm3
Surface area of casting = 29756 mm2
[Table 7.2] – Pattern Allowances
32. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 23
Considering a cylindrical riser with H/D = 1,
Riser Volume =
Surface area of riser = 1.25
Freezing ratio,
/
1.25 2
/0. 3 0.0255
0.25
3
233376
1.0712 ∗ 10
3
Substituting the values of X & Y in Caine’s relation, we get
0.0255
0.1
1.0712 ∗ 10
3
0.06
1.08
By rearranging the terms and solving the above equation we get,
62.19166 62
Feeder neck dimensions due to geometry restrictions gives neck diameter, 25
The empirical relations for top riser neck dimensions are:
Length of neck, max /2 and 0.2 ∗
∴ 12.6
Modified surface area of casting due to neck placement is 29756 0.785 ∗ 25 ∗ 25
29265.375 mm2
.
New casting modulus is
.
7.97
Modulus of feeder,
∗ .
12.4
here, . Hence, design is safe.
Also, 0.785 ∗ 0.785 ∗ ∗ 193171.23 mm3
∴ Casting Yield, ∗ 100 54.70 %
Simulating the above results in Efoundry and optimizing the hotspots we have the final feeder
dimensions as:
64 ; 25 12.2
, 52.427%; 12.8 6.25
Although modulus of feeder neck is less than modulus of casting, its effective modulus is
always higher than the casting due to high heat transfer zone in the surrounding region of the
neck. Hence, to compensate for the required diameter according, 1.1 ∗ , a taper
is provided on the neck with the diameter at feeder connection equal to 30 mm.
33. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 24
7.2.3 Sprue, Runner and Gate Design
The route path which molten metal follows to enter into the mould cavity is pouring basin to
sprue to base well to runner to in-gates to mould cavity. The design of such path is as follows:
Weight of casting, = 0.658 *2 + 0.692 = 2.008 kg
Pouring time, √ = 1.417 s
taking, = 10 s (approximately)
Mass density of the molten metal, = 2439.8 kg/m3
Assuming top gating system with the entire sprue to be located in the cope itself, effective
metal head (sprue height), = 101.7 mm
Efficiency factor, = 0.73 (gating system with two runners)
∴ Choke area,
.
. ∗ ∗ . ∗ √ ∗ . ∗ .
= 79.8542 mm3
∴ Choke diameter, = 10.085 mm. let, 15 mm
Hence, choke area, = 176.625 mm2
.
Assuming the gating ratio of 1:2:1,
choke area = gate area
∴ gate area, ∗ (20 * thickness) which gives thickness of gate
10 mm. The gate is here located at the parting line because of 50 mm depth of the mould
cavity. so that metal enters the cavity at the mid plane thereby reducing erosion.
[Fig.7.2] – Geometry with top feeder
Top Feeder Φ64 x 64 mm
Feeder Neck
Φ25 x 12.2 mm
34. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 25
The area of runner obtained using the gating ratio accounts for a tapered runner section which
has been neglected here due to small job geometry and considering the pattern manufacturing
considerations.
Using Bernoulli’s equation and considering 10 mm height for the pouring basin from the top
of the cope,
Sprue area at top, ∗ 176.625 ∗
.
.
186.0064
∴ sprue top diameter, = 15.39 mm. let, 30 mm
Also, sprue base well diameter is 2.5 ∗ = 50 mm
The mould cavity so designed is shown in the figure below. The actual cope and drag patterns
are prepared from wood and those used for preparing the mould cavity are also shown below.
[Fig.7.3] – Mould Box Section
[Fig.7.4] – Drag Pattern
Locating pins
Junction
pattern
Runner
35. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 26
7.2.4 Moulding Sand
The moulding sand used for foundry practice is obtained commercially. The properties and
the composition of the sand used are:
Sr.No. Description Range
1. Grain Size AFS 70 to 90
2. Green Compressive Strength 700 to 1500 gm/cm
3. Permeability 90 to 120
4. Compactibility 35 to 48
5. Moisture 3.5-5%
6. VM 4.5-5.5%
7. Active Clay 8-10%
7.3 Simulation in Efoundry
Efoundry has inbuilt video classes which provides a good insight into casting design and
simulation technique. The video classes have been conducted by Dr. B Ravi (IIT-B). It also
includes an online library which contains technical papers and dissertations which have been
carried out in the same field. Certain ebooks are also available which are published by Dr.B
Ravi. It also holds an alloy database which gives the composition, properties, applications and
standards for ferrous and non-ferrous metals. Besides, it also provides online tutorial for
designing a casting component. A number of 3D models are also available in the library which
can be directly used or edited online in the CollabCAD software for dimensions. Online
simulation for solidification of casting for a given geometry can be done in the Sim Lab option.
A number of case studies are also uploaded to provide a better insight into the actual casting
industry problems.
[Table 7.3] – Moulding Sand Properties and Composition
[Fig.7.5] – Cope Pattern with riser and sprue
SprueTop
Feeder
36. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 27
The steps to carry out simulation in efoundry are as follows:
1. Login to efoundry website
2. Prepare the geometry file in .stl (stereolithography) file format
3. Select the metal and sand mesh parameters
4. Upload the model and interpret the simulation results.
7.6(a) – step 1
7.6(b) – step 2
37. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 28
The temperature contours obtained from efoundry for the selected ‘X’ junction are shown in
fig.7.6. These contours locate the hotspot region in the given geometry where white region is
7.6(c) – step 3
7.6(d) – step 4
[Fig 7.6] – Simulation steps in Efoundry
38. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 29
the hottest of all and indicates probable location of shrinkage cavity. The simulation is done
with the following parameters:
Metal : Aluminium
Sand Mesh : Coarse
Initially, the geometry was prepared in Creo 2.0 and was imported to ‘.stl’ (stereolithography)
format. The ‘.stl’ file was then imported to ‘Sim Lab’ in efoundry and then simulated.
Fig 7.6(a) – indicates the solidification zone in the junction without feeder. It is seen that at the
centre of the junction a local hotspot formation leads to unavailability of feed metal during
solidification causes and hence, causes shrinkage cavity of large volume.
[Fig.7.7] – Solidification simulation in Efoundry
7.7(a)
7.7(b); D = 62 7.7(c); D = 64
AMBIENT 582 ⁰C
39. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 30
Fig 7.6(b) – indicates the solidification zone in the junction with the feeder of diameter D = 62
mm. It is seen that the hotspot is not completely removed from the junction and has some
hotspot zone left inside the casting. Indicated by dark yellow regions.
Fig 7.6(c) – indicates the solidification zone in the junction with the feeder of diameter D = 64
mm. It is seen that the hotspot is completely removed from the junction and the hotspot has
completely shifted inside the feeder.
7.4 Experimentation in Foundry
The entire mould cavity was prepared in the foundry using the available green sand. Metal was
poured into the cavity and the casting was then analysed internally by cutting it diagonally to
observe internal defect (shrinkage cavity). Below figures show the various steps followed for
experimentation.
[Fig.7.8(a)] – Sand Preparation [Fig.7.8(b)] – Facing Sand application for Drag
[Fig.7.8(c)] – Rammed Drag [Fig.7.8(d)] – Mould cavity in Drag
40. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 31
The following pouring process was carried out at M/s. Utsav Metals, Nadiad. The parameters
noted during pouring condition are as follows:
Actual Pouring time 26 seconds
Actual Weight of Casting 2.150 kg
Al Alloy Composition (%)
Al Si Cu Zn Pb
83.41 11.24 2.88 0.99 0.18
[Fig.7.8(e)] – Cope preparation by placing feeder & sprue [Fig.7.8(f)] – Venting in the cope
[Fig.7.8(g)] – Final Drag & Cope Assembly [Fig.7.8(h)] – Metal Pouring
[Fig.7.8(i)] – Final Cast Product
[Table 7.4] – Pouring Condition Parameters and Alloy Composition
41. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 32
Chapter 8
EXPERIMENTAL RESULTS AND DISCUSSIONS
In order to validate the designed feeder for the job, two mould cavities are prepared pertaining
to the same jobs where one job is fed with open type top feeder whereas the other has no feeder.
The cavities are prepared inside a single mould box so that it ensures same pouring condition
for both the jobs and hence, provides a base for comparison. This is an effective means of
observing how feeder affects the quality of casting and helps in minimizing internal defects.
The runner and gate is separated from the two jobs and each of the job is cut diagonally across
the junction to observe the shrinkage cavity located inside it. The discussions related to each
of the job is as follows:
Job without feeder
[Fig.8.1] – Cast job without feeder
[Fig.8.2] – Cut Plane Section in the job without feeder
Cutting Plane
42. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 33
A clean surface at the top of the junction indicates no riser/feeder location at its top. Due to the
breakage of mould cavity while preparing the cope, the cavity lost its corners on the top two
arms. This caused accumulation of the molten metal at those points. The cavity broke due to
the sticking of large amount of sand at the corners. One of the reasons for this is improper draft
available for pattern removal. High moisture content in the sand or excessive stickiness in the
moulding sand can also be its cause.
It is seen from the above cut-plane sections of the job that porous holes have been developed
at the center of the junction. Distributed shrinkage porosity is observed as in a case of long
freezing range alloy. This was predicted by the efoundry simulation as well which shows that
the location of hotspot lies at the center of the junction. Although, a bigger shrinkage cavity
was expected at the hotspot zone which was in reference to a short freezing range alloy i.e.
pure metal, the cavity obtained here is in the form of porous holes. The large amount of molten
metal being available at the edges of the junction allowed the junction to solidify progressively
thereby, reducing the amount of shrinkage. Large amount of shrinkage in terms of surface
defects is visible in the spread out metal area at the arms of the geometry.
Due to misalignment of the cope and drag after assembly, parting line shift is also observed.
The amount of parting line shift is about 3 to 5 mm. Parting line shift is never desired in the
casting.
This indicates clearly that if appropriate amount of metal is available for the casting during
solidification then shrinkage cavity can be eliminated.
Job with feeder
[Fig.8.3] – Cast job with feeder
43. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 34
A circular spot on the top of the job indicates the feeder location on the job. Here also, the
breakage of cavity at the edges of the junction caused the metal to spread out of the job
randomly. This resulted in increase of the job size and hence the solidification as expected per
simulation is not obtained. A cut section of the top feeder is shown below. It is seen that there
is no cavity formed inside it.
Due to increase in the size of the job, the feeder would not have been able to feed the casting
and hence, it worked oppositely by feeding itself from the job. This may have been possible as
the shrinkage cavity pores have shifted from the parting line towards the top of the casting i.e.
towards the neck. If appropriate radiograph of the casting can be carried out, the actual
shrinkage zones could be observed accurately.
The shrinkage pores obtained here are least dense and smaller in size as compared to those in
the previous case by certain extent. There is a possibility that the neck may have solidified
earlier than the hotspot and hence, feeding path is blocked. Moreover, a sink is observed at the
top surface of the feeder which shows that some metal has been fed to accommodate the
[Fig.8.4] – Cut Plane Section in the job with open top feeder
[Fig.8.5] – Top Feeder and its Cut Plane Section
44. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 35
shrinkage. This dip is easily visible in the cut plane section of the feeder indicated by a
curvature at the top of the surface.
In general, it is expected that no shrinkage be formed inside this part, but due to various issues
related to sand preparation, mould making and pattern making makes it difficult to achieve for
inexperienced researchers. If the given job is casted out completely under the guidance of a
proper experienced foundryman, then a more in-depth analysis can be performed.
Moreover, theoretical casting yield,
* 100
∴
0.658 ∗ 2
2.008
∗ 100 65.5%
and actual casting yield from pouring ,
∴ ′
0.658 ∗ 2
2.150
∗ 100 61.2 %
It is also clear that actual casting yield is less than that of the theoretical casting yield since the
actual amount of metal poured is always more than that of theoretical value due to various
factors like mould cavity errors, oxidation loss through the sand mould, volumetric contraction
of the molten metal absorption of metal in the sand. Feeding of metal during solidification also
accounts to this factor.
45. SIMULATION AND EXPERIMENTATION IN CASTING FEEDER DESIGN
Page | 36
Chapter 9
CONCLUSION
The selected ‘X’ junction is simulated in Efoundry to locate the hotspot formation. An
appropriate feeder is designed using Caine’s method and keeping in mind the rules laid out by
Campbell for feeder design. The feeder diameter so obtained is 62 mm. The feeder is then
added to the geometry and is simulated till the hotspot gets shifted to the feeder itself. The final
feeder diameter is 64 mm where the entire hotspot formation is in the feeder itself. The feeder
selected is an open type top feeder.
A mould cavity is prepared with two jobs of the ‘X’ junction where one job is assigned a feeder
and the other has no feeder. A single mould box ensures that the pouring condition remains
same for both the jobs and hence, allows them to be compared experimentally for shrinkage.
The shrinkage cavity in the junction without a feeder is obtained in the form of small amount
of porosity holes distributed across the parting line or the core of the junction. This confirms
to the hotspot location obtained in the Efoundry simulation. An actual type of cavity as expected
is not obtained due to the actual alloy composition whereas efoundry simulated for pure Al.
One of the other reasons is that while preparing the cope portion of the mould, the cavity as
desired was not obtained and it broke along the corners and edges of the arms of the job.
Moreover, parting line shift was also encountered. This caused the metal to spread out along
its edges. The extra metal so available aided the solidification feed paths of the job and hence,
reduced the shrinkage cavity size. This indicates that if appropriate amount of metal is available
during solidification, then feed metal paths exist and it tends to minimize the shrinkage cavity.
The shrinkage cavity in the junction with feeder is shifted above the parting line and it moved
towards the feeder neck. This indicates that feed paths were available from the top feeder.
Moreover, a spherical dip was observed in the top surface of the feeder which also indicates
that feeding had taken place. The only setback here was the parting line shift and the mould
cavity breakage in the cope portion along the edges and corners of the junction. This increased
the size of the job to be cast which may have increased its modulus than the feeder. This may
have caused a reversed feed path removing the cavity from the feeder. Again, a drop in the
modulus of the feeder neck due to such reasons caused the neck to solidify earlier which
blocked all feed path from the feeder to the job and vice versa.
Taking proper care while mould preparation can produce appropriate results as obtained from
the simulation.
46.
Page | 37
FUTURE WORK
Current work is limited to a junction with single hotspot which can be further expanded for
a junction with multiple hotspot.
Optimization of the feeder can be done by employing the available numerical optimization
techniques and other casting simulation software. This ensure maximum yield.
The desired junction can be tested for other materials and observed for the same defect. It
can be specially checked for steels or CI where graphitization causes negative shrinkage.
Use of other methods like Vector Element Method, Modulus method, Naval Research
Laboratory method, etc. and others should be employed. The feeder dimensions so obtained
can be compared for best feeding efficiency and yield.
A benchmark product can be taken as a case study where there are more than one hotspot
and the feeder dimensions obtained by different method can be tested and compared. The
main motto here should be to consider the economic factor associated with the cast product.
Improved feeder design by incorporating insulated or exothermic feeder which gives high
feeding efficiency can also be validated.
47. Page | 38
REFERENCES
1. Amitabha Ghosh, Asok Kumar Mallik, Manufacturing Sciences, Affiliated East-West
Press Pvt. Ltd., 1981
2. Dr. P. C. Mukherjee, Methods of Improving Strength and Quality of Castings
3. O. P. Khanna, Foundry Technology, Dhanpat Rai Publications, 2011
4. P. N. Rao, Manufacturing Technology – Vol. 1 (Foundry, Forming and Welding),
McGraw Hill Education (India) Private Limited
5. Richard W. Heine, Carl R. Loper, Philip C. Rosenthal, Principles of Metal Casting,
Tata McGraw Hill Education Pvt. Ltd.
6. Elizabeth Jacob, Dundesh S. Chiniwar, Savithri S, Manoj M., and Roschen Sasikumar,
Simulation-Based Feeder Design for Metal Castings, Indian Foundry Journal, Vol.59,
No.12, December 2013, p.39-44
7. M. Jagdishwar, Casting Feeder Design Optimization Based on Feed Path and
Temperature Analysis, M.Tech Dissertation, IIT Bombay, 2012
8. D. Joshi, B. Ravi, Classification and Simulation Based Design of 3D Junctions in
Castings, AFS Transactions 2009
9. E-Foundry Academy, Casting Design and Simulation Video Lecture,
h // f d ii b i