Study on using Casting Simulation Software for Design and Analysis of Riser Shapes in a Solidifying Casting Component

Abstract

Filling and solidification of molten metals are very complex and difficult to simulate correctly by conservative methods. For a large industrial application, it needs an alternate approach that is fast, reliable and user-friendly. In current casting industries, product development paradigm is shifting from traditional trial-and-error in the workshop to computer-aided casting design and simulation package by a computer(s). Computer-aided casting simulation plays an important role in the paradigm of new product development by way of modeling entire casting processes and reveals a dynamic behavior of casting scheme in working conditions. This study, highlighting is given on using casting simulation software which helps foundry industries to design and analysis the size and shape of the riser. Intended for simulation simplification in this study, grain size of mold green sand, casting material quality, casting process parameters are deliberated identical for all design schemes. Only the shape and dimensional variances of sprue/risers are taken into considerations for defects analysis. It is found that defects such as micro and shrinkage porosities, and improper solidification, are directly related to gating and risers system. Casting simulation software is used for mold filling and solidification analysis and it is observed that the proposed gating and risers system design will improve casting results with small defects. From this study, the conclusion can be stated that taper sprue design, also acts as a riser, with an additional four small risers that will produce a small fraction of porosity inside of the casting part. Validation of simulation, in the future, will be proved through experimental trials in the foundry shop.

Certain investigation on feasibility of developing riser less ductile iron castings

“…By using simulations to evaluate defect tendency, costly trial-and-error experiments can be minimized. Once validated, models can be used for consistency in quality across production runs by predicting potential defects [4].…”

Evaluasi Efisensi Riser Untuk Bentuk Riser Samping yang Berbeda Menggunakan Metode Simulasi Casting

“…Shuvo dan Manogharan (2021) melakukan penelitian pengaruh tiga bentuk riser berbeda; ellipsoid, spherical, dan silindris untuk aplikasi pada riser atas [3]. Penelitian lain yang dilakukan oleh Malik dkk (2020) membandingkan bentuk riser taper silindris dan silindris untuk aplikasi pada riser atas dengan riser juga diposisikan sebagai sprue [10]. Wang dan Yao (2022) membandingkan bentuk riser silindris, silindris dengan riser neck, dan riser-less untuk aplikasi riser atas [11].…”

Dynamic Simulations of Manufacturing Processes: Hybrid-Evolving Technique

“…The melt fluid flows into the mould and its low turbulence/laminar characteristics, mushy and solidification zone (with its metallurgical aspects), and also the final solid zones need to be simulated accurately to achieve desired results. These sophisticated numerical simulations have already found their way into the mainstream industrial tools [15][16][17] to enable the simulation of chain processes for production lines. Although the early multi-phase simulations of these processes are an important part of the framework, the details of these simulations are not discussed here in this paper.…”