Metal casting modeling software for small scale enterprises to improve efficacy and accuracy

Rajkumar, I.; Rajini, N.

doi:10.1016/j.matpr.2021.02.542

Cited by 6 publications

(4 citation statements)

References 20 publications

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“…However, direction of the gating normal to the main runner was considered in those works. The results depicted backflow of molten metal in both experimental and numerical simulation approaches, which created formation of discontinuities in the casting products [18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Applicability of Angular Orientations of Gating Designs to Quality of Sand Casting Components Using Two-Cavity Mould Set-Up

Rajkumar

Rajini

Prabhu

et al. 2021

Trans Indian Inst Met

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This study aimed to examine integrity of two-cavity sand casting products in relation to angular orientation of gating design. Two angular orientations of 60° and 45° were investigated experimentally and numerically, and compared with the efficiency of a 90° gating system. The FLOW three-dimensional (3D) simulation was conducted to detect smooth filling and describe pattern of molten aluminium LM4 (Al-Si5Cu3) alloy flow. From the results obtained, turbulent flow was observed with vortex, which created larger surface gap to allow air entrapment in molten metal. For both instances, casting discontinuities such as blow holes, pin holes, sponge shrinkage, sand inclusions and dross were observed on the cut 2 mm machined surfaces of the moulded components with various degrees of intensity. Visual analysis, optical microscopy, ultrasonic and X-ray measurements were conducted to check accuracy of the experimental components. All the defect detection methods depicted fewest manufacturing defects with 45° angular orientation, which was attributed to uninterrupted flow of molten metal and low backflow strain. The component with 90° exhibited significant defects, due to turbulent flow, entrapment of air bubbles, lack of mould filling and uneven solidification. These factors consequently caused irregular cracks in the material. Therefore, Practically, 45 o angular orientation of gating design with two-cavity mould set-up is hereby recommended for optimum/best quality sand casting of aluminium LM4 (Al-Si5Cu3) alloy components, as required in many manufacturing companies.

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Section: Introductionmentioning

confidence: 99%

Applicability of Angular Orientations of Gating Designs to Quality of Sand Casting Components Using Two-Cavity Mould Set-Up

Rajkumar

Rajini

Prabhu

et al. 2021

Trans Indian Inst Met

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“…In addition, the hollow cavity in sand mold is not designed close to the desired shape but is designed in an approximate shape for casting. [6][7][8][9][10] After solidification, excess removal of the gating system and risers as post-casting process to cut the casting according to the desired shape are essential processes of sand casting. That means, more materials are wasted than materials desired shape, and the time and cost for the post-casting process are quite large, which is the biggest disadvantage of sand casting.…”

Section: Introductionmentioning

confidence: 99%

“…That means, more materials are wasted than materials desired shape, and the time and cost for the post-casting process are quite large, which is the biggest disadvantage of sand casting. [1][2][3][4][5][6][7][8][9][10][11][12][13] To reduce the amount of wasted material, it is necessary to design a gating system suitable for the desired shape and to verify and supplement the gating system through casting simulation.…”

Section: Introductionmentioning

confidence: 99%

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Jin

2023

Advances in Mechanical Engineering

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Bottom-up gated filling system was performed to produce worm wheel through a sand casting of zinc alloy. It was a symmetrical design in which two worm wheels were cast at once, the worm wheel was erected in the direction of gravity and had a gating system in which molten zinc alloy were poured from below. The recovery rate of the designed mold cavity was 60%. Casting analysis was performed to check that the worm wheel was sequentially filled without turbulent flow as the molten zinc alloy passed through the gate. Though the speed of the molten zinc alloy initially poured was unstable, it became stabilized while maintaining a constant speed due to the continuous inflow. The results of directional solidification were confirmed. An integrated mold cavity pattern was fabricated by 3D printer, and sand mold were manufactured accordingly. A sound worm wheel without defects could be fabricated through sand casting.

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“…The simulation result was compared with the experimental test, thus verifying the precision of the virtual experiments. In another article [ 2 ], the problem of residual stresses was identified and resolved at design stage. Such action may lead to the development and application of appropriate process control methods during production in order to reduce premature destruction of the casting in exploitation conditions.…”

Section: Introductionmentioning

confidence: 99%

Technological Optimization of the Stirrup Casting Process with the Use of Computer Simulations

et al. 2022

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The article presents the optimization of high-pressure die casting process technology for equestrian stirrups with the application of computer simulation. In the initial stage, the output technology was analyzed, and on the basis of a series of virtual experiments the cause of defects in the casting was highlighted. The optimization process includes different designs of a gating system. Additionally, the casting application properties were evaluated in an exploitation simulation, taking into account predicted defects resulting from the casting and solidification process. Based on the conducted analyses, technological changes were made to the casting technology design allowing the defects occurring in the original technological concept to be removed.

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Metal casting modeling software for small scale enterprises to improve efficacy and accuracy

Cited by 6 publications

References 20 publications

Applicability of Angular Orientations of Gating Designs to Quality of Sand Casting Components Using Two-Cavity Mould Set-Up

Applicability of Angular Orientations of Gating Designs to Quality of Sand Casting Components Using Two-Cavity Mould Set-Up

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Technological Optimization of the Stirrup Casting Process with the Use of Computer Simulations

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