Computation of feed-paths for casting solidification using level-set-method

Sutaria, M. P.; Gada, Vinesh H.; Sharma, Atul; Ravi, B.

doi:10.1016/j.jmatprotec.2012.01.019

Cited by 23 publications

(12 citation statements)

References 30 publications

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“…Gupta and Sharma (1993) developed different models and analyzed the failure by computing the reliability measures such as availability, cost estimation, mean time to failure. Sutaria et al (2012) discussed the capability to predict the temporal evolution of the interface and to identify that multiple hotspots is validated with an industrial aluminum-alloy lug casting. Venkatesan et al (2005) discussed and developed a program for finite element modelling of casting solidification.…”

Section: Introductionmentioning

confidence: 99%

Sensitivity analysis for casting process under stochastic modelling

Kumar¹

2015

10.5267/j.ijiec

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The present paper studies the reliability analysis of the casting process in foundry work using a probabilistic approach. As foundry industries in many developing countries suffer from poor quality of casting due to improper management, lack of resources and wrong working methods followed, which results in the decrement of productivity. Hence, to ensure the quality and productivity, favorable steps must be taken. The considered casting system has four main types of defects; namely mold shift, shrinkage, cold shut and blowholes. The complete casting system can fail due to the misalignment of the mold and combination of defects such as shrinkage and blow holes and can also fail by defects of shrinkage, blow holes and cold shut, simultaneously. The system is analyzed with the help of the supplementary variable technique and Laplace transformation. The availability, reliability, mean time to failure, sensitivity analysis and costeffectiveness have been evaluated for the considered system. The results have been shown with the help of graphs, which predicts the behavior of the casting process system when any one of the defect or more than one defect appears.

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Section: Introductionmentioning

confidence: 99%

Sensitivity analysis for casting process under stochastic modelling

Kumar¹

2015

10.5267/j.ijiec

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“…These methods are based on manipulation of huge matrices and iterative calculations, making them computationally intensive [28]. Another limitation is that the temperatures computed at the end of the solidification do not uniquely reveal all hot-spots since minor hot-spots, which develop early, may disappear by the end of the solidification [29].…”

Section: Previous Workmentioning

confidence: 99%

“…Moreover, the movement of the interface is governed by the imbalance of the heat-flux at the interface i.e., Stefan condition. Recently, Sutaria et al [29] proposed level-set-method (LSM) based computation of feed-paths and hot-spots using combined Eulerian-Lagrangian framework. Later, Sutaria and Ravi [34] proposed gradient vector method for feed-path and hotspot location under uniform boundary condition, and showed it to be more accurate than the MVM, and faster than LSM.…”

Section: Previous Workmentioning

confidence: 99%

“…6a was selected to validate the results of GVM in terms of hot-spot computation by comparing with the shrinkage defect observed in experimental casting. Further, the performance of GVM in terms of feed-path computation was compared with MVM [2] and LSM-based casting solidification simulation [29]. The casting has a thickness of 0.1 m and its mass is 3.8 kg.…”

Section: Benchmarkingmentioning

confidence: 99%

“…6b. The temperature contours at the end of solidification obtained using finite volume method (FVM) as proposed by Sutaria et al [29] is shown in Fig. 7.…”

Section: Benchmarkingmentioning

confidence: 99%

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Computation of casting solidification feed-paths using gradient vector method with various boundary conditions

Sutaria

Ravi

2014

Int J Adv Manuf Technol

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In the present work, a computationally efficient numerical approach called gradient vector method (GVM) is proposed to visualise feed-paths and to evaluate the design of feeding systems with various thermal boundary conditions. It involves the computation of liquid-solid interfacial heat flux vector using an analytically derived solution to phase changeheat transport equation. The resultant of flux vectors gives the direction of the highest temperature gradient, which is continuously tracked to generate complete feed-paths. The originating points of the feed-paths indicate hot-spots that manifest as shrinkage defects. Mathematical models are proposed to handle the effect of various boundary conditions like insulation or exothermic sleeves around feeders and chill blocks in mould. The accuracy of GVM in predicting the location of shrinkage porosity defect has been validated by pouring and sectioning benchmark castings. Computation of feed-paths using this method was found to be an order of magnitude faster than level-set method for casting solidification simulation. The implementation of the method in three dimensions and its application to an industrial casting are also presented.

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