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Casting Defects Identification and Solution

by Simulation and Practical approach

Submitted By

Giriraj Jigneshbhai Shah


(Enrolment No. 130340721003)

Supervised By

Mr. Bhautik R. Pabani


Assistant professor, Mech. Engg. Dept.,
Narnarayan Shastri Institute of Technology,
Ahmedabad, Gujarat

A Thesis submitted to
Gujarat Technological University
In partial fulfilment of the requirements for
The Degree of Master of Engineering in [Thermal Engineering]
May-2015

Narnarayan Shastri Institute of Technology, Jetalpur, Ahmedabad

1
CERTIFICATE

This is to certify that research work embodied in this project report entitled Casting
Defect Identification and Solution By Simulation and Practical Approchwas carried
out by Mr. Giriraj Jigneshbhai Shah (Enrollment No. 130340721003) at Narnarayan
Shastri Institute of Technology, Ahmedabad for partial fulfillment of M.E. degree to be
awarded by Gujarat Technological University. This research work has been carried out
under my supervision and is to the satisfaction of department.

Date:

Place: Ahmedabad

Internal Guide:

Mr. Bhautik R. Pabani


Assistant Prof. (Mech Engg.)
Narnarayan Shastri Institute of Technology
Jetalpur, Ahmedabad, Gujarat

Mrs Neha H Patel


H.O.D.
MECHANICAL ENGINEERING DEPARTMENT
NARNARAYAN SHASTRI INSTITUTE OF TECHNOLGY, AHMEDABAD

DR. SHARDADEVI MANDALAPU


PRINCIPAL
NARNARAYAN SHASTRI INSTITUTE OF TECHNOLGY, AHMEDABAD

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DECLARATION OF ORGINALITY

I hereby certify that I am the sole author of this project report and that neither any
part of this nor the whole of the project report has been submitted for a degree to any other
University or Institution.

I certify that, to the best of my knowledge, my project report does not infringe
upon anyones copyright nor violate any proprietary rights and that any ideas, techniques,
quotations, or any other material from the work of other people included in my project
report, published or otherwise, are fully acknowledged in accordance with the standard
referencing practices. Furthermore, to the extent that I have included copyrighted material
that surpasses the bounds of fair dealing within the meaning of the Indian Copyright Act,
I certify that I have obtained a written permission from the copyright owner(s) to include
such material(s) in my project report and have included copies of such copyright
clearances to my appendix.

I declare that this is a true copy of my project report, including any final
revisions, as approved by my project report review committee.

Date:

Place: Ahmedabad

Giriraj Jigneshbhai Shah


(Enrolment No.130340721003)
Verified By
Mr. Bhautik R. Pabani
INTERNALSUPERVISER
Asst. Prof. in Mech. Dept.
N.S.I.T., Jetalpur, Ahmedabd.

3
PROJECT REPORT APPROVAL

This is to certify that research work embodied in this entitled Casting Defect
Identification and Solution By Simulation and Practical Approch was carried out by
Giriraj Jigneshbhai Shaha (130340721003) at Narnarayan Shastri Institute of Technology
is approved for award of the degree of Master of Engineering in Mechanical (Thermal
Engineering) by Gujarat Technological University.

Date:

Place:

Examiner(s):

............................. .............................
( ) ( )

4
AKNOWLEDGEMENT

It is my privilege to be the student of M.E. Thermal stream in Narnarayan Shastri


Institute of Technology, Ahmedabad. My heartfelt thanks to Prof. Bhautik R. Pabani, my
guide who helped me with his precious suggestions and rich experience. He was a real source
of inspiration and guidance and it is due to his co-operation and support that I am able to
successfully carry out my dissertation work in the due course of time.

I would also like to thank PROF. MANISH PATEL, Assistant Professor in Mechanical
Department, N.S.I.T., Jetalpur for his valuable support and guidance.

I would also like to thank Ms. NEHA H. PATEL, Head of Mechanical Department,
N.S.I.T., and Ahmedabad for his constant guidance, encouragement and academic support.

Finally, I would like to thank my parents for always being understandable and
encouraging me to pursue my goals with effort. Thank is a very small words for this. Last but
not the least thanks to almighty for giving me such a platform.

Giriraj J. Shah
M.E. (Thermal Engineering)
Enroll. No.: 130340721008
N.S.I.T., Jetalpur,
Ahmedabad.

5
Sr. No List Of Figure Page. No.
Figure 1.1 Production steps in a typical sand casting process 5
Figure 1.2 Schematic illustration of a sand mold 6
Figure 1.3 Examples of sand casting 7
Figure 1.4 Some defects in sand casting 8
Figure 1.5 Example of porosity 9
Figure 1.6 Cold-shut defect 9
Figure 1.7 Misrun defect 9
Figure 1.8 Typical gating/riser system 10
Figure 1.9 Too large feeding distance can cause shrinkage 12
Figure 2.1 Micro shrinkage 13
Figure 2.2 Interdenritic Shrinkage 13
Figure 2.3 Ginkage 13
Figure 2.4 Types of Shrinkage porosity 14
Figure 2.5 Major steps in casting Simulation 14
Figure 2.6 Surface Defect 15
Figure 2.7 Gas porosity defects 16
Figure 2.8 Comparison of Experimental result and ProCast Result 17
Figure 4.1 Die Box (Drag) 22
Figure 4.2 Die Box (Cope) 22
Figure 4.3 Core of product 23
Figure 4.4 Shrinkage defect 23
Figure 5.1 Taper in Sprue 25
Figure 5.2 Classification of gating system based on parting plane orientation 27
Figure 5.3 Classification of Gating system based on position of ingate 28
Figure 5.4 Runner profiles 29
Figure 5.5 New Gating Dimension 29
Figure 5.6 Steps needed to make a simulation 33
Figure 5.7 3D Model 34
Figure 5.8 Meshing In Mesh Cast 34
Figure 5.9 Tetra Mesh 35
Figure 5.10 Structure of Pro cast 35
Figure 5.11 Import of Mesh File in PRE-CAST 36

Figure 5.12 Mould body 36


Figure 5.13 Part with Sprue& Gate inside of Mold 37
Figure 5.14 Interface between mould and cast 37
Figure 5.15Air cooling to all mould surfaces

Figure5.16 Inlet velocity to pouring cup

Figure 5.17 Selecting gravity filling process

Figure 5.18 Selecting gravity filling process

Figure 5.19 Initial conditions for mould

Figure 5.20 Initial conditions for cast component

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Figure 5.21 Defining run parameter

Figure 5.22 Post Processing Results in View CAST

Figure 5.23Time V/s Temperature Contour at different nodal points

Figure 5.24Fraction solid

Figure 5.25 Output result form the ProCAST

Figure 5.26 Location of porosity in actual Part

Table No. List of Table Page


No.
Table 1 Casting Data 21
Table 2 Chemical Composition Of S.S. 304 21

7
Chapter 1

Introduction

Casting is a manufacturing process for making complex shapes of metal materials in


mass production. There are two main consecutive stages, filling process and solidification
process, in casting production. In filling process gating system composed of pouring cup,
runner, sprue, sprue well and ingate, is designed to guide liquid metal filling. Casting process
design is important for production quality and efficiency.

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It is unavoidable that many different defects occur in casting process, such as porosity
and incomplete filling. quality. Casting quality is heavily dependent on the success of gating
system design, which currently is conducted mainly relied on technicians experience.
Therefore there is a need for the development of a computer-aided casting process design tool
with CAD, simulation, and optimization functions to ensure the quality of casting

The objective of the research presented in this thesis is to optimize gating systems
based on CAD and simulation technology with the goal of improving casting quality such as
reducing incomplete filling area, decreasing large porosity.

Therefore in the thesis, a CAD model of part design and after its being converted to
casting model, the first objective is to evaluate castability of the casting design. Then runner
and risers are presented parametrically. By varying each parameter, all CAD models will be
obtained. After analyzing simulation results, the original gating system design will be
optimized to improve casting quality.

1.1Background
In this chapter include introduction to sand casting process. Then, considerations
required for casting process design are stated. Then After casting quality and some common
defects are discussed. Then after gating system and basic riser design are explained in detail.

1.1.1 Sand Casting Processes


Sand casting consists of placing a pattern in sand to make an imprint, incorporating a
gating system, filling the resulting cavity with molten metal, allowing the metal to cool until
it solidifies. Sand casting is still the most popular form of casting.

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Figure 1.1 Production steps in a typical sand casting process

Basically sand casting process consists of the six steps in this process:

1. Place a Pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system.

3. Remove the pattern.

4. Fill the mold cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mold and remove the casting.

Figure 1.2 Schematic illustration of a sand mold

1.1.2 Sand Casting Process Design


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The typical sand casting process design consists of the following steps.

1.1.2.1 Sand Selection

The Sand Casting molding process utilizes a cope and drag flask set-up. The mold
consists of sand, clay and water. When the water is added it develops the bonding
characteristics of the clay, which binds the sand grains together. When applying pressure to
the mold material it can be compacted around a pattern, which is either made of metal or
wood, to produce a mold having sufficient rigidity to enable metal to be poured into it to
produce a casting. The process also

The sand must exhibit the following characteristics:

Flowability: The ability to pack tightly around the pattern.

Plastic Deformation: Have the ability to deform slightly without cracking so that the pattern
can be withdrawn.

Green Strength: Have the ability to support its own weight when stripped from the pattern,
and also withstand pressure of molten metal when the mold is cast.
Permeability: This allows the gases and steam to escape from the mold during casting.
1.1.2.2 Parting line
Parting line is the line or plane separating the upper and the lower part of molds. In
general, the parting line should be along a flat plane rather than be contoured.
1.1.2.3 Pattern design
The pattern is a replica of the object of cast, used to prepare the cavity into which
molten material will be poured during the casting process. Patterns used in sand casting may
be made of wood, metal, plastic or other materials. Patterns are made to exacting standards of
construction, so that they can last for a reasonable length of time.
The mold is made by packing some readily formed aggregate material, such as
molding sand, around the pattern. When the pattern is withdrawn, its imprint provides the
mold cavity, which is ultimately filled with metal to become the casting. During the design
process of pattern, some considerations should be taken.

1.1.2.4 Core design

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Cores are forms, usually made of sand, which are placed into a mold cavity to form
the interior surfaces of castings. Thus the void space between the core and mold-cavity
surface is what eventually becomes the casting. The following picture shows the sand cores.

Figure 1.3 Examples of sand casting

1.1.2.5 Gating system design and optimization


The preparation of molten metal for casting is referred to simply as melting. Melting
is usually done in a specifically designated area of the foundry, and the molten metal is
transferred to the pouring area where the molds are filled.
After pouring metal, it will flow through the gating system until the cavity is fully filled.
Then the metal begins to cool and solidify with the occurrence of shrinkage. Riser system is
designed to compensate such shrinkage. Gating system has great effects on the final quality
of casting.

1.1.3 Defects in Sand Casting Process


During the metal casting process, various defects can develop. They are shown in figure
1.4. It is important to improve the casting quality by eliminating or minimizing the effects caused
by those defects.

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Figure 1.4 Some defects in sand casting
Two common defects in sand casting process are produced in porosity and incomplete
filling. Porosity in castings is due to bubbles being trapped during solidification. It may be
caused by shrinkage, or gases, or both. There are many factors contribute to the development
of porosity such as the entrapped air during filling, blowholes from unvented cores, dissolved
gases from melting, etc.

Figure1. 5 Example of porosity

Incomplete filling is primarily caused by poor fluidity of molten metal and main
defects in the form of a cold shut or misrun. A cold shut occurs when two streams of molten
metal coming from opposite directions meet, but dont fuse completely. A misrun occurs
when the molten metal does not completely fill a section of the mould cavity.

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Figure 1.6 Cold-shut defect

Figure 1.7 Misrun defect

The casting quality is heavily dependent on the success of gating system design. Next
the gating system will be introduced in detail.

1.1.4 Gating System


A key element in producing quality castings is the proper design and sizing of the
gating and riser systems . A foundry can produce the best quality molds, cores and molten
metal and still end up with a poor quality casting by using poorly designed gating and riser
systems. A typical gating system is shown below.

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Figure 1.8 Typical gating system
1.1.4.1 Gating System
The main objective of a gating system is to lead clean molten metal poured from ladle
to the casting cavity, ensuring smooth, uniform and complete filling.

1.1.4.1.1 Requirements of Gating System


There are many factors affecting the design of an ideal gating system. It is a better
design of the gating system that it can be removed easily from the casting after filling. The
gating system should be designed in such a way to promote the directional solidification.
After meeting other requirements of gating system, it will also need lower yield.

1.1.4.1.2 Runner
Runner is typically located in the drag of the casting. Because molten metal often
changes its direction during the flow process in the runner, turbulence often accumulates. For
a good runner design, it must not promote turbulence. There are some useful experience in
real foundry such as always use radiuses corners, never sharp corners, etc. As described
earlier, two primary requirements of a gating system are to prevent cold shuts and misruns
during mold filling.

1.1.4.1.3 Gates
Gates are the inlets into the mold cavity. The gates can be no thicker than the casting
section to which they are attached. Even more it usually is best to have the gates slightly
thinner than the casting section. If the gating system is not completely filled during the entire
pour, it will not function correctly, and defective castings can result.

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Chapter 2

Literature review
MathiahThingnanam [1] he describe the, some theoretical aspects of the casting defects are
explain. The shrinkage Porosity and Blow holes study in details. In casting, shrinkage areas
are low pr regions and gas bubbles are highpr regions.
Types Of Shrinkage Porosity:
i. Macro shrinkages
ii. Micro shrinkage
iii. Intermediate type
iv. Ginkage: It is combination of gas and shrinkage.

Figure 2.1 Micro shrinkage Figure 2.2 Interdenritic Shrinkage

Figure 2.3Ginkage
Causes for the shrinkage:
i. Macro shrinkages straight forward i.e. lack of supply feed metal to the shrinkage
area of the casting.
ii. Micro shrinkage are due lack of Interdenritic feeding.
iii. Ginkage It is newly coined word to indicate the combination of both gas and
shrinkage.

General location where the shrinkage occurs:


i. By concave defect on the as cast surface internal shrinkage.

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ii. In side of the heavy section which are suffering from lack of feeding.

DrB. Ravi [2], he Describe the five distinct steps of casting simulation process: Data
gathering, Method design, Numerical simulation, Method optimization and project closure.

Figure 2.5 Major steps in casting Simulation


1. Data Gathering:- this is the most important stage. Since incorrect or
incomplete data will lead to incorrect simulation and wrong conclusion. The
problem must be defined first, to need ascertain need of simulation.
2. Metal design and modeling:- In this stage the method design is solid model to
convert the as-cast part model in to a 3D model of the mold containing part
cavities as well as feeders, gating channels, cores.
3. Numerical simulation:- This is a main stage of casting simulation. The first set
is the correct generation of FEM mesh. The mesh must be covered the entire
model without gapes. The second set of inputs is boundary condition like the
heat transfer co-efficient. There are maintain three types of interfaces. Metal-
Model, metal environment and mould environment.
4. Method Optimization:- The simulation results are first compared with observe
defects to the cause of defects. Then the design method are modified the
simulation program and after the casting simulation.
5. Project closure:- This includes generating a method report, analysis report,
image of major steps and result.
William G.[3], Describe the surface and gas porosity casting defect causes and their
corrections. Leading edge of metal flow is too cold in this cause surface defects are produces.
. Gas trapped in the metal flow during die fill in this causes gas porosity defects are produce.

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Figure 2.6 Surface Defect
Corrections of Surface defects are:
1. Increasing Die temperature, Check the following condition for cold dies.
Slow cycle time
Add overflows for more heat
2. Reduce filling time
Increasing gate area
Increasing hydraulic pressure
3. Change flow pattern
Direct flow at the problem area by moving the gate
Change gate velocity (first increasing)
Change gate design to direct flow in a different direction

Figure 2.7 Gas porosity defects


Correction of Gas porosity defects are:
1. Check runner for smooth flow path
No sharp corners
No blind ends
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2. Vacuum working
Vacuum channels located at last point to fill
Filters cleaned and open
3. Gas comes from trapped air
Consistent pour rates
Delay after pour (set right to minimize splashing in shot sleeve)
Acceleration to slow shot speed correct
4. Check vents
Right side
Vent kept open
Located at last point of fill
Vent go to the edge of the die
Tushar Patel [4] in this paper describes the FE analysis using Pro-CAST software for casting
Shell core drum . During the production porosity defects is produces. Tool maker microscope
is used to the measure the location and size of porosity.

Figure 2.8Comparison of Experimental result and ProCast Result


Working steps of Tool Maker Microscope Working steps:
1st Put the work piece on the table of microscope.
2nd set the lens of microscope at starting of defect.
3rd start the light and rotate the table as per the defect geometry.
4th rotate the screw of table as per defect.
5th Get the result.

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Tool Maker Microscope automatically generates the graph of defect as well as the perfect
location of defect withrespect to X-Y-Z axis.
FE Analysis using Pro-CAST: Steps needed to make a simulation process.
STE 1. 3D CAD Modeling
STEP 2. Meshing with Mesh CAST
STEP 3. Data input to Pro-CAST Define Run parameter for die casting simulation
STEP 4. Calculation: Initial when fluid is poured in mould.
STEP 5.Analyzing result.
Then after comparison of Experimental result and pro cast result.Experimental results
are taken by using Tool Maker Microscope we get the % of porosity is 12.30% and in FE
Analysisby using ProCAST we get the % of Porosity is 13.86% variation % of porosity is
0.126%.
BhupendraChudasma [5]in this paper, to study the solidification behavior of material and
detection of hot spots in castings with the help of Pro-CAST casting simulation software.
The main inputs for the casting simulation process are:
1) Thermo-physical properties (density, specific heat, and thermal conductivity of the cast
metal as well as the mould material, as a function of temperature).

2) Boundary conditions (i.e. the metal mould heat transfer coefficient, for normal mould as
well as feed aids including chills, insulation and exothermic materials).

3) Process parameters (such as pouring rate, time and temperature).


Any optimization problem has three basic ingredients:
Optimization variables, also called design variables denoted as vector x.

Cost function, also called the objective function, denoted as f (x).

Constraints expressed as equalities or inequalities denoted as gi(x)


John Campbell [6] in this paper, study about the seven feeding rule of casting.
1. Heat transfer Requirement: The Modulus of the feeder must be equal to or
greater than the modulus of the casting. In other terms the modulus of feeder
equals 1.2 times the modulus of the casting.
2. Volume Requirement: The feeder must contain sufficient liquid to satisfy the
volume contraction requirement of casting.
3. Junction Requirement: The junction between the casting and feeder must not
create a hot-spot.
4. Feed path Requirement: There must be a path to allow feed metal to reach the
regions that need it.
5. Pressure requirement: Sufficient pressure must be applied to all parts of
solidifying metal to inhibit the nucleation and growth of volume defects.

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The pressure gradient Requirement: There must be sufficient pressure differential to
cause the feed metal to flow and flow must be in the correct direction.
Harshil Bhatt [7] in this paper, Casting simulation comprises three modulus namely
solidification, flow and coupled simulation. Solidification simulation can be used to detect
location of hot spot and show the feed paths. Flow simulation can be idea about velocity of
molten metal during mold filling, filing time. Flow simulation helps to locate flow related
defects like cold shunt and Misrun.

B. Ravi [8] in this paper, the implementation of modified technique based on the quality
control research is a must to avoid defects in the products. For this he initially connected
information of rejection and then analysis these with pareto chart and giving proper remedies
of control rejection.

Pierre-Marie Cabanne [9] in this paper thermal analysis basic knowledge are provided.

WHAT IS THERMAL ANALYSIS USED FOR?

To control the chemical composition: C equivalent, %C, %Si (Si equivalent);


To define the pouring temperature: T liquidus + superheat;
To characterize the liquid iron:
Carbide formation tendency or need to optimize inoculation: T, Te Low
Micro-shrinkage tendency: R,
Inverse chill tendency: Ts.

Changes in these three characteristics are easily detected when the composition of the charge
is modified. In most cases,

A decrease in undercooling (_T) and, then, a reduction of the risk of chill;


A reduction of the recalescence (R) and, then, a reduction of the risk of micro-
shrinkage;
_The achievement of the Te Low value well beyond the Te White value which
eliminates the risk of carbide formation;
The achievement of a Ts value higher than the Te White value and the avoidance
of inverse chill.

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Chapter 3

Problem Definition

Motivation:

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In the casting of metals, the phenomenon of solidification plays an important and
decisive role in determining the quality of cast components. Castings are widely used in
many industrial sectors and employ processes that are gravity or pressure based. In all cases,
the goal is the production process of near net shaped components. However, the casting
process is not clean and reliable; there are lots of parameters that affect the final product
quantitatively and qualitatively. Solidification simulation helps in providing more reliable.
Shrinkage defect is the major cause of rejection in the majority of castings. Over the
years many researchers have used various numerical methods to predict the occurrence of
shrinkage in castings.

Goal:

Implementation of Gating design parameter to prevent shrinkage defect in casting of


the hardware part, and validate it with simulation result.

Research Objectives:

The objectives of this Research are:

a) Problem Identification in hardware part during casting.


b) Parameter changes for gating & riser.
c) Find Pouring result and simulation result help of casting.
d) Pouring result by practical approach.
e) Comparison between both Practical and Simulation results.

Chapter 4

Data Collection from Industry

4.1 Casting Data from Industry:

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The Technical data for mould and Coupling material are enlisted in table no. given below
with different features of actual casting condition of Coupling.

Sr. No. Parameter Specification


01 Weight of Coupling (6 Pieces) 1.050kg
02 Sprue, Gate total Weight with Coupling (6 Pieces) 1.550kg
03 Sprue, Gate total Weight 0.5kg
04 Pouring Time 10 sec
05 Pouring Temperature 1500 1550 C
06 Density of Stainless Steel 7900 Kg/ M 3
07 Specific Heat 500 J/Kg.k
08 Co. Thermal Expansion 0.000018 C
09 Mould Size 250x250 mm2
10 Gate Lenth 21mm
11 Pouring Height 40mm
Table 1 Casting Data

4.2 Material Specification:


The Material which used in the company is S.S. 304 and the details about the material are
show in Table
Chemical %
Material Name C Mn P S Si Cr Ni
S.S.304 0.08 2.0 0.045 0.030 1.0 18 to 20 8 to
10.5
Table 2 Chemical Composition Of S.S. 304
4.3 Different View Of Die:

The different views of cope and drag section of Die prepared for Union Coupling part(Six
cavities ) are shown in figures given below.

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Figure 4.1 Die Box (Drag)

This drag portion of the mould box as shown in figure

Figure 4.2 Die Box (Cope)

Figure shows the cope portion of the Die box and set on the drag such that the cavities for
casting on cope and drag matches to each other perfectly.

4.4 Core of product:

Then after use of this die are producing core of that particular part. After producing the core,
the shell core casting is produced. During casting process shrinkage defects are produced. fig
are shown in core of product.

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Figure 4.3 Core of product

During Casting process shrinkage defect are produces that shrinkage defect are shown
in fig

Figure 4.4 Shrinkage defect

Chapter 5

Proposed Gating Design and Simulation in Pro Cast

26
If a proper design of the gating system is to be evolved, then a procedural and logical
approach as described below should be adopted. It is described in steps.

1. Estimation of optimum pouring time.

2. Calculation of sprue-choke area.

3. Selection of appropriate gating ratio.

4. Calculation of runner/ingate size.

5.1 Estimation of optimum pouring time:

Decide Pouring time approximately about 50 sec. for casting weighing more than 100kg and
order of 20 to 30 sec for the smaller casting weighing more than 5kg.

Estimate the total weight of metal to be poured in to the casting. The thumb rule is that about
2.5 to 3 times the casting weight is to be poured.

Pouring time t=K W =1.2 175=16 s

Where, W is the weight of casting 175 gm .

K varies from about 1.2 for 100lb casting to about 0.4 for 100,000lb casting

5.2 Calculation of Sprue - Choke area:

5.2.1 Sprue

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Figure 5.1 Taper in Sprue

In a properly tapered sprue, the liquid metal lies firmly against its walls during cascading and
it reduces turbulence and eliminates aspiration.

A1
A2
=

h2
h1

Where, A1 is area at sprue entrance

A2 is area at sprue exit

h1 is the level of liquid metal above the sprue entrance, and

h2 is the level of liquid metal above the sprue exit.

5.2.2 Choke:

Choke is the part of gating system which possesses smallest cross-sectional area. The area at
the sprue exit which it is the least is known as choke area and can be calculated from the
following relation based upon the Bernoullis theorem.

W 175
Ca= Ca= =11.16 mm 2
c . d . t 2 gH 0.4 7.85 16 2 9.81 50

Where, Ca is Choke area

W is the weight of casting 0.175 gm

c is nozzle coefficient 0.4 to 0.7

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d is density of liquid metal 7.85 Kg/ mm3

t is pouring time 16s

H is effective liquid metal head. 50 mm

5.3 Selection of appropriate gating ratio:

Gating ratio is

Area of Sprue : Total runner area : Total ingates area

Depending on the ratio of total cross sectional area of sprue exit, runner and ingate , gating
system is divided into pressurized system and non-pressurized system.

5.3.1 Pressurized System:

In this system pressure is maintained at the ingates by the fluid. In order to achieve this total
gate area should be less than the sprue exit area. In other words choke is located at the ingate.
This system keeps gating channels full of metal. Due to pressurization the flow separation is
absent in the system also air aspiration is minimized. The filling rate and yield increase.
However, high metal velocity will cause turbulence.

5.3.2 Non Pressurized System:

In this system choke is located at the sprue exit. Hence the sprue exit area is less than the total
gate area, for example 1:2:2, 1:4:4. Due to lower velocity, filling rate will be less. The process
yield increases but it suffers from the disadvantage of flow separation.

Gating ratio for some of metals is as follows

I. Aluminium

Pressurized syatem 1:2:1

Unpressurized syatem 1:3:3

II. Brass 1 : 1 : 1 to 1 : 1 : 3

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III. Ductile iron 10 : 9 : 8

IV. Gray Cast iron

Pressurized System 1 : (1.3) : (1.1)

V. Steel 1:2:2

Gating ratio and positions of ingates should be such that liquid metal fills the mold cavity
just rapidly to avoid laps, misrun, and cold shunt in thin sectioned casting, and reduced
turbulences and mold erosion in casting of thicker sections.

5.4 Gating Design:

Figure: 5.5 New Gating Dimension

5.6 Design Steps of Gating System:


The size of the sprue fixes the flow rate. In other words, the amount of molten metal
that can be fed into the mold cavity in a given time period is limited by the size of the
sprue.

The sprue should be located at certain distance from the gates so as to minimize
velocity of molten metal at ingates. Often, the flow leaving the sprue box is turbulent;
a longer path and a filter enable the flow to become more laminar before it reaches the
first gate.

Rectangular cross-section sprue is better than circular one with the same cross-
sectional area, since critical velocity for turbulence is much less for circular sections.
In addition, vortex formation tendency in a sprue with circular cross section is higher.

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Sprue should be tapered by approximately 5% minimum to avoid aspiration of the air
and free fall of the metal.

Ingates should be located in thick regions.

Locate the gates so as to minimize the agitation and avoid the erosion of the sand
mold by the metal stream. This may be achieved by orienting the gates in the direction
of the natural flow paths.

Multiple gating is frequently desirable. This has the advantage of lower pouring
temperatures, which improves the metallurgical structure of the casting. In addition,
multiple gating helps to reduce the temperature gradients in the casting.

Rectangular cross section of runners and ingates are generally preferred in sand
castings.

Runner extensions are used in most castings to trap any dross that may occur in the
molten metal stream.

A relief sprue at the end of the runner can be used to reduce the pressure during
pouring and also to observe the filling of the mold.

5.7Numerical simulation of solidification process:


Governing Equation:

Numerical simulation of solidification process requires following steps:


Formulating an accurate physical description of the casting and solidification process
in the mathematical form.

Use of accurate values for thermal properties of the materials involved.

Performing a suitable numerical analysis to obtain temperature relationships at


specified space co-ordinates in the casting and mold, so as to predict shrinkage
defects.
For solidification simulation of the casting several assumptions are usually made, these
include:
The filling is instantaneous, that is solidification starts after complete filling.

The liquidus and solidus temperature are well defined, so that plotting of beginning of
freeze and end of freeze curve is possible.

31
Only one mode of heat transfer (conduction) is assumed, whereas all three modes
(conduction, convection and radiation) are present in actual solidification process.
Governing equation for solidification of casting is given by,
T
. . = K T + Q
t
Where, C - specific heat, K - thermal conductivity,
T - Temperature, t time,
Q - Rate of internal heat generation, - density.
Heat generated (assuming that latent heat is released at the rate of formation of the solid
fraction fs ) in casting is given by,
d fs
Q=L
dt
Where, L - total latent heat, fs - solid fraction ratio, t - time.
Boundary conditions
For solving governing equation boundary conditions are necessary. In solidification
simulation, generally following three types of boundary conditions are used:
(1) Specified Temperature: In this type the temperature at the boundary is specified.
Tc [ Hc ( x , t ) ] =Tm ( x , t )
Where, x - Spatial co-ordinate,
t - Time co-ordinate,
Tc - Temperature of the casting at the interface,
Tm - Temperature of the mold at the interface,
Hc - Enthalpy of casting.
(2) Specified Heat Flux
In this type heat flux at the boundary is specified. Continuity of heat flux across the
sand-metal interface gives,
Tc Tm
Kc =Km
n n
Where, n - co-ordinate normal to the sand-metal interface,
T - temperature.
subscripts c and m are for casting and mold.
(3) Convection Type
Heat loss at the boundary is expressed in terms of heat transfer coefficient:

32
dT
Q = K x=bound=h(T )
dx
Where, q - heat flux, h - interface heat transfer coefficient,
To - ambient temperature, x - spatial co-ordinate.

The model has been performed on the Solid works 2009 version and then after the analysis
works has been performed on the Pro CAST 2011 version.

5.8 FE Analysis using ProCAST


Figure shows a flowchart of simulation process of the casting. The castings geometries presented
here were meshed with MeshCAST, which requires the Generation of a surface mesh before
meshing the enclosed region with tetrahedral elements.

3D

Model

Meshing
WithMesh Cast

Data Input Pro


Cast

Calculation of
Pro Cast

Analyzing
Result In View
Cast

Figure: 5.6 Steps needed to make a simulation

33
STEP 1 3D Mode:

Figure 5.7 3D Model

The model has been performed on the Creo 2.0 version and then after the analysis works has
been performed on the Pro CAST 2014 version.

STEP 2.Meshing with MeshCAST

Figure 5.8 Meshing In Mesh Cast

34
Mesh CAST generates a 3-D tetrahedral mesh using the Finite Element Method . A triangular
surface mesh of the object is the prerequisite for Mesh CAST's "tetrahedral mesh" generation.
Based upon IGES, PARASOLIDS, STEP, or STL model, Mesh CAST can generate the
triangular surface mesh. Alternatively, Mesh CAST can use the surface mesh from your CAD
or CAE package as input for tetrahedral mesh generation. It is important to note that working
with Mesh CAST always begins by opening a file. After the file has been loaded, we begin
working at the corresponding work step in the process. From this entry point to the final
generation of the tetrahedral mesh, the steps we follow and the Mesh CAST tools we use will
be the same regardless of the type of input file used.

Figure 5.9 Tetra Mesh

The step by step procedure for the analysis is given below.

Step 1: Pre processing in Pre-CAST

Figure 5.11 Import of Mesh File in PRE-CAST

35
Step 2: Selection for Mould Material
Apply Mould material as Silica Sand.

Figure 5.12Mould body

Step 3: Apply cavity filling by molten metal


After filling molten metal in mould, the cast body ofSix part of hardware, sprueand gate are
show in given below.

Figure 5.13 Part with Sprue& Gate inside of Mold

36
Step 4: Apply interface between mould and cast component

Figure 5.14 Interface between mould and cast

Step 5: Apply air cooling to all mould surfaces

Applying air cooling to the all mould surfaces as soon as beginning of pouring of molten
metal into mould.

37
Figure 5.15 Air cooling to all mould surfaces

Step 6: Apply inlet velocity to pouring cup

Apply inlet velocity of 8.5 mm/s to the pouring cup.

Figure 5.16 Inlet velocity to pouring cup

Step 7: Apply inlet temperature to pouring cup


The actual pouring temperature is in the range of 1400-1550 C. So, select 1500 C as inlet
temperature to pouring cup.

38
Figure 5.17 Inlet temperature to pouring cup

Step 8: Define Process for Filling


Define gravity filling as process for filling. The molten metal from ladle is poured into the
mould cavity under the action of gravity force only.

Figure 5.18 Selecting gravity filling process

Step 9: Apply Initial Condition for Mould

Figure 5.19 Initial conditions for mould

39
Step 10: Apply initial condition for Cast Component

Figure 5.20 Initial conditions for cast component

Up to this stage, all information is being provided to the ProCAST before applying the run
parameter.

Step 11: Define Run Parameter

Apply run parameter for Hardwear part.

Figure 5.21: Defining run parameter

40
Step 12: Post Processing Results in View CAST

We have temperature distribution at section taken on Y-Y plane. A color zone in the cavity
indicates the temperature distribution of poured metal at different time interval.

Figure 5.22: Post Processing Results in View CAST

Step 13: Time V/s Temperature contour from the analysis


From the above analysis we have Time V/s Temperature contour at different nodal points,
which is given in graph shown in figure 5.22.

Figure 5.23 Time V/s Temperature Contour at different nodal points

Step 14: Fraction solid

Figure 5.24: Fraction solid

41
Above fraction solid figure shows that after completion of mould filling there is a possibility
of uneven solidification because metal in the middle portion of the casting are in the liquid
stage while outside of the (or far away from the) part, it has been cooled. The fraction solid
scale is varying from 0.000 to 1.000 and 0.000 means completely liquid phase and 1.000
means completely solid phase.

Step 15: Output result from ProCAST

Output result of shrinkage porosity is given below in figure 5.24.

Figure 5.25 Output result form the ProCAST

Finally, after completion of analysis process, we have the solution in the form of
identification of exact location of the shrinkage porosity in part body as shown in figure 5.24.

5.10Comparison of FEA and Experimental Results for Validation

Comparison of Experimental and FE Analysis Results is shown here in the figure 5.25.

42
Location of Shrinkage Defect

Figure 5.26 Location of porosity in actual Part

From above finite element analysis and experimental results comparison, we can say that FE
Analysis results fairly matches with experimental results. So FE Analysis is a good tool to
replace costly and time consuming experimental work for optimization.

Chapter 6

RESULTS AND DISCUSSION

6.1Introduction

43
After completing modelling, meshing, finite element analysis, validation for Coupling cage
we got the finite ways for improving the quality of sand casting process used for cage. Even
we are highly focusing on solution by FEA; we also cover another terms through which
productivity of foundry will improve. So let, discuss the results obtained from above
workout.

Chapter 7

CONCLUSION

44
Chapter 8

FUTURE SCOPE OF WORK

45
46
REFERENCES

[1] MatthiasThingnanam,How to solve casting defect in the aluminum gravity die casting in
the shop floor Aluminum Foundry Consultancy

[2] Dr B. Ravi, Casting Simulation Best Practices Transactions of 58 th IFC, (Ahmedabad)


2010

[3] William G. et al, Die casting defect Troubleshooting Guide, 2003

[4] Tushar M. Patel, Analysis and Validation of Gravity Die Casting Process using
ProCAST International Journal of Application or Innovation in Engineering & Management
(IJAIEM),Volume 2, Issue 4, ISSN 2319 4847, April 2013
[5] Bhupendra J. Chudasama, Solidification Analysis and Optimization Using Pro-Cast
International Journal of Research in Modern Engineering and Emerging Technology
(IJRMEET), Vol. 1, Issue: 4,ISSN: 2320-6586, MAY: 2013
[6] John Campbell et al The Feeding of Castings EAA - European Aluminium Association
Date of Issue: 1994
[7] Harshil Bhatt, Design Optimization of Feeding System and Solidification Simulation for
Cast Iron 2nd International Conference on Innovations in Automation and Mechatronics
Engineering (ICIAME), 2014
[8] Dr. B. Ravi, A Holistic Approach to Zero Defect Castings Technical Paper for 59TH
INDIAN FOUNDRY CONGRESS, Chandigarh, February 2011

47
[9] Pierre-Marie Cabanne, Thermal Analysis :Usefull Technique for the foundaryman REV
March 2006

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