Beruflich Dokumente
Kultur Dokumente
Submitted By
Supervised By
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
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:
2
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
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):
............................. .............................
( ) ( )
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AKNOWLEDGEMENT
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.
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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
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Figure 5.21 Defining run parameter
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Chapter 1
Introduction
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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.
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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:
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
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.
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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.
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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.
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
The casting quality is heavily dependent on the success of gating system design. Next
the gating system will be introduced in detail.
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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.
1.1.4.1.2 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 2.3Ginkage
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.
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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.
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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
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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).
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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.
Changes in these three characteristics are easily detected when the composition of the charge
is modified. In most cases,
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Chapter 3
Problem Definition
Motivation:
22
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:
Research Objectives:
Chapter 4
23
The Technical data for mould and Coupling material are enlisted in table no. given below
with different features of actual casting condition of Coupling.
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)
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.
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
Chapter 5
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.
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.
K varies from about 1.2 for 100lb casting to about 0.4 for 100,000lb casting
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
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
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d is density of liquid metal 7.85 Kg/ mm3
Gating ratio is
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.
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.
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.
I. Aluminium
II. Brass 1 : 1 : 1 to 1 : 1 : 3
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III. Ductile iron 10 : 9 : 8
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.
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.
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.
The liquidus and solidus temperature are well defined, so that plotting of beginning of
freeze and end of freeze curve is possible.
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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:
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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.
3D
Model
Meshing
WithMesh Cast
Calculation of
Pro Cast
Analyzing
Result In View
Cast
33
STEP 1 3D Mode:
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.
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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.
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Step 2: Selection for Mould Material
Apply Mould material as Silica Sand.
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Step 4: Apply interface between mould and cast component
Applying air cooling to the all mould surfaces as soon as beginning of pouring of molten
metal into mould.
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Figure 5.15 Air cooling to all mould surfaces
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Figure 5.17 Inlet temperature to pouring cup
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Step 10: Apply initial condition for Cast Component
Up to this stage, all information is being provided to the ProCAST before applying the run
parameter.
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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.
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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.
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.
Comparison of Experimental and FE Analysis Results is shown here in the figure 5.25.
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Location of Shrinkage Defect
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
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
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Chapter 8
45
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REFERENCES
[1] MatthiasThingnanam,How to solve casting defect in the aluminum gravity die casting in
the shop floor Aluminum Foundry Consultancy
[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
48