Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation

Nazma Sultana; Md. Rafiquzzaman; Younosur Rahman; Apurba Das

doi:doi:10.11648/j.ijmea.20180606.12

| Peer-Reviewed

Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das

Published in International Journal of Mechanical Engineering and Applications (Volume 6, Issue 6)

Received: 13 September 2018 Accepted: 2 November 2018 Published: 28 January 2019

Views: Downloads:

Download PDF

Share This Article

Twitter
Linked In
Facebook

Abstract

Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.

Published in	International Journal of Mechanical Engineering and Applications (Volume 6, Issue 6)
DOI	10.11648/j.ijmea.20180606.12
Page(s)	150-160
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2019. Published by Science Publishing Group

Keywords

Shrinkage Porosity, Improper Solidification, Air Entrapment, Mould Erosion, Click2cast

References

[1]	Johnston, R. E. (1989). Design of experiments: Taguchi in the foundry. Transactions of the American Foundrymen's Society, 97, 415-418.
[2]	Kumar, P., &Gaindhar, J. L. (1995). Off‐line quality control for V‐process castings. Quality and reliability engineering international, 11(3), 175-181.
[3]	Masoumi, M., Hu, H., Hedjazi, J., &Boutorabi, M. (2005). Effect of gating design on mold filling. Transactions of the American Foundry Society, 113, 185-196.
[4]	Choudhari, C. M., Padalkar, K. J., Dhumal, K. K., Narkhede, B. E., & Mahajan, S. K. (2013). Defect free casting by using simulation software. In Applied Mechanics and Materials, 313, 1130-1134. Trans Tech Publications.
[5]	Bhatt, H., Barot, R., Bhatt, K., Beravala, H., & Shah, J. (2014). Design optimization of feeding system and solidification simulation for cast iron. Procedia Technology, 14, 357-364.
[6]	Lee, P. D., Chirazi, A., & See, D. (2001). Modelling micro porosity in aluminium–silicon alloys: a review. Journal of light metals, 1(1), 15-30.
[7]	Katzarov, I. H. (2003). Finite element modeling of the porosity formation in castings. International Journal of Heat and Mass Transfer, 46(9), 1545-1552.
[8]	ManjunathSwamy, H. M., Nataraj, J. R., & Prasad, C. S. (2012). Design Optimization of Gating System by Fluid Flow and Solidification Simulation for Front Axle Housing, International Journal of Engineering Research and Development, 4(6), 83-88.
[9]	Shafiee, M., Rizuan, M., Hashim, M. Y., & Said, M. N. Effects of gating design on the mechanical strength of thin section castings, Proceedings of (MUCEET2009) Malaysian Technical Universities Conference on Engineering and Technology June 20-22, MS Garden, Kuantan, Pahang, Malaysia.
[10]	Hu, B. H., Tong, K. K., Niu, X. P., and Pinwill, I. (2000), Design and optimization of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation, Journal of Materials Processing Technology, 105,128-133.
[11]	Dai, X., Yang, X., Campbell, J., & Wood, J. (2003). Effects of runner system design on the mechanical strength of Al–7Si–Mg alloy castings. Materials Science and Engineering: A, 354(1-2), 315-325.
[12]	Ahmad, R., &Hashim, M. (2011). Effect of vortex runner gating system on the mechanical strength of Al-12Si alloy castings. Archives of Metallurgy and Materials, 56(4), 991-997.
[13]	Naveenkumar, B. (2014). S. Kodli,“Design Optimization of Gating System by Fluid Flow and Solidification Simulation for Pump Casing by Sand Casting”. IJREAT International Journal of Research in Engineering & Advanced Technology, 2(4).
[14]	Hashim, M. Y., Mohd Amin, A., & Vijay, R. R. Effects of runner diameter on the mechanical strength and porosity distribution of thin section castings. In: Regional Conference on Engineering Mathematics, Mechanics, Manufacturing & Architecture (EM3ARC 2007).
[15]	Ochulor, E. F., Adeosun, S. O., &Balogun, S. A. (2015). Effect of Gating Sprue Height on Mechanical Properties of Thin Wall Ductile Iron. World Academy of Science, Engineering and Technology, International Journal of Chemical, Molecular, Nuclear, Materials and Metallurgical Engineering, 9(2), 360-367.
[16]	Narkhede, B. E., Choudhari, C. M., & Mahajan, S. K. (2014). Modelling and Simulation for Optimum Design and Analysis of Riser in Sand Casting with Experimental Validation. In Applied Mechanics and Materials, 465, 657-661. Trans Tech Publications..
[17]	C. M. Choudhari, B. E. Narkhede and S. K. Mahajan, A hybrid approach for casting process simulation by combining FEM and VEM for defect minimization with experimental validation, during 7-8-9 February, 2014, 62nd Indian Foundry Congress, Ahmedabad, India
[18]	Pequet, C., Rappaz, M., &Gremaud, M. (2002). Modelling of micro porosity, macro porosity, and pipe-shrinkage formation during the solidification of alloys using a mushy-zone refinement method: applications to aluminum alloys. Metallurgical and Materials Transactions A, 33(7), 2095-2106.
[19]	S. Sulaiman and A. M. S. Hamouda. (2004). Modelling of the thermal history of the sand casting process, Journal of Materials processing technology, 150(3), 242-254.
[20]	Shahria, S., Tariquzzaman, M., Rahman, M. H., Al Amin, M., & Rahman, M. A. (2017). Optimization of Molding Sand Composition for Casting Al Alloy. International Journal of Mechanical Engineering and Applications, 5(3), 155-161.
[21]	Behera, R., Kayal, S., &Sutradhar, G. (2011). Solidification behavior and detection of Hotspots in Aluminium Alloy castings: Computer Aided Analysis and experimental validation. International journal of applied engineering research, 1(4).
[22]	Nimbulkar, S. L., &Dalu, R. S. (2016). Design optimization of gating and feeding system through simulation technique for sand casting of wear plate. Perspectives in Science, 8, 39-42.
[23]	Zhi, X., Han, Y., & Yuan, X. (2015). Casting process optimization for the impellor of 200ZJA slurry pump. The International Journal of Advanced Manufacturing Technology, 77(9-12), 1703-1710.
[24]	Choudhari, C. M., Narkhede, B. E., & Mahajan, S. K. (2014). Methoding and simulation of LM 6 sand casting for defect minimization with its experimental validation. Procedia Engineering, 97, 1145-1154.
[25]	Ravi, B. (2008). Casting simulation and optimisation: benefits, bottlenecks and best practices. Indian Foundry Journal, 54(1), 47.
[26]	Roa, P. N. (2001). Manufacturing Technology, Foundry, Forming, and Welding.

Cite This Article

Plain Text BibTeX RIS

APA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. (2019). Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. International Journal of Mechanical Engineering and Applications, 6(6), 150-160. https://doi.org/10.11648/j.ijmea.20180606.12

Copy | Download

ACS Style

Nazma Sultana; Md. Rafiquzzaman; Younosur Rahman; Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int. J. Mech. Eng. Appl. 2019, 6(6), 150-160. doi: 10.11648/j.ijmea.20180606.12

Copy | Download

AMA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int J Mech Eng Appl. 2019;6(6):150-160. doi: 10.11648/j.ijmea.20180606.12

Copy | Download

@article{10.11648/j.ijmea.20180606.12,
  author = {Nazma Sultana and Md. Rafiquzzaman and Younosur Rahman and Apurba Das},
  title = {Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {6},
  number = {6},
  pages = {150-160},
  doi = {10.11648/j.ijmea.20180606.12},
  url = {https://doi.org/10.11648/j.ijmea.20180606.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20180606.12},
  abstract = {Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.},
 year = {2019}
}

Copy | Download

TY  - JOUR
T1  - Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation
AU  - Nazma Sultana
AU  - Md. Rafiquzzaman
AU  - Younosur Rahman
AU  - Apurba Das
Y1  - 2019/01/28
PY  - 2019
N1  - https://doi.org/10.11648/j.ijmea.20180606.12
DO  - 10.11648/j.ijmea.20180606.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 150
EP  - 160
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20180606.12
AB  - Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.
VL  - 6
IS  - 6
ER  -

Copy | Download

Author Information

Nazma Sultana

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh
Md. Rafiquzzaman

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh
Younosur Rahman

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh
Apurba Das

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh

Download PDF

Sections

Plain Text BibTeX RIS

APA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. (2019). Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. International Journal of Mechanical Engineering and Applications, 6(6), 150-160. https://doi.org/10.11648/j.ijmea.20180606.12

Copy | Download

ACS Style

Nazma Sultana; Md. Rafiquzzaman; Younosur Rahman; Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int. J. Mech. Eng. Appl. 2019, 6(6), 150-160. doi: 10.11648/j.ijmea.20180606.12

Copy | Download

AMA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int J Mech Eng Appl. 2019;6(6):150-160. doi: 10.11648/j.ijmea.20180606.12

Copy | Download

@article{10.11648/j.ijmea.20180606.12,
  author = {Nazma Sultana and Md. Rafiquzzaman and Younosur Rahman and Apurba Das},
  title = {Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {6},
  number = {6},
  pages = {150-160},
  doi = {10.11648/j.ijmea.20180606.12},
  url = {https://doi.org/10.11648/j.ijmea.20180606.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20180606.12},
  abstract = {Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.},
 year = {2019}
}

Copy | Download

TY  - JOUR
T1  - Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation
AU  - Nazma Sultana
AU  - Md. Rafiquzzaman
AU  - Younosur Rahman
AU  - Apurba Das
Y1  - 2019/01/28
PY  - 2019
N1  - https://doi.org/10.11648/j.ijmea.20180606.12
DO  - 10.11648/j.ijmea.20180606.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 150
EP  - 160
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20180606.12
AB  - Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.
VL  - 6
IS  - 6
ER  -

Copy | Download