International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 04 Issue: 07 | July -2017
p-ISSN: 2395-0072
www.irjet.net
Casting Defect Identification and Its Solution by Niyama Simulation Bhautik R. Pabani1, Pratik R. Vyas2, Mitesh D. Patel3, Pratik A. Vataliya4 1234Assistant
Professor, Department of Mechanical Engineering, Narnarayanshastri Institute of Technology,Jetalpur ------------------------------------------------------------------------***----------------------------------------------------------------------process design is important for production quality and Abstract- Increasing productivity and improve quality with efficiency.
reduce in cost, many foundries are exploring software packages, which help to reduce the need of trials and prototyping. However there is always a deference in actual and predicted location of defects, especially for new materials, shapes and processes.
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.
Casting defects caused due to evolution and entrapment of gases during casting process and many other reason. This project aims to develop a systematic approach for prediction for defect in casting based on available knowledge, experience of experts in this area and with use of mold own software like auto-cast, pro-cast. Also the final solution is given by doing experimental as well as simulation comparison The initial study will involve studying major defect in certain hardware part, principle of their formation, causes and remedies and preparing a knowledge base. The focus is on large size defect in sand casting. Mathematical equations were used for gating system for mold filling and for temperature drop of metal during mold filling. The user inputs include the 3D model of the casting (in the form of IGES _le) and relevant pouring parameters.
2. LITERATURE REVIEW Feng Liu et al [1] in this paper, with the aid of parametric modeling technology of runner and riser are modeledparametrically. By varying each parameter, it is easy to get different casting CAD models. These models output data populate the orthogonal matrix, which is used in the orthogonal array testing strategy to define the most suitable combinations of runners and risers parameters. After inputting the completed orthogonal matrix data and all CAD models into the simulation software the simulation result can be obtained.
The layer-by-layer filling of mold cavity is simulated by Niyama criteria and display of instantaneous temperature of metal, defect developed in the mold cavity. The software result is compared with practical casting result in the future work. This enables the user to identified and gives predictable solution of sand casting defect.
Marco Aloe et al [2] observed that Gating systems, overflows, venting channels can be optimized using numerical simulation. Solidification related defects can also be predicted taking into account cooling channels and die cycling so as to accurately reproduce production conditions. ProCAST readily addresses all these issues but also includes advanced features to better assess the casting quality.
Keywords: Casting Defect, Niyama Simulation, Auto cast, Core casting, creo modeling.
1. INTRODUCTION
Mohammad Sadeghi et al [3] observed that ProCAST software used to simulate the fluid flow and solidification step of the part, and the results were verified by experimental measurements. By this Paper he concludesthat 1) Comparison of the experimental and simulation results indicates that defects in the pieces are placed at the predicted places by simulation. 2) If the die temperature is reduced from the optimum temperature range, probability of cold flow defects and air porosities increase. 3)
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
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