Design Optimization of Feeding System and Solidification Simulation for Cast Iron

Bhatt, Harshil; Barot, R.S.; Bhatt, Kamlesh Kumar; Beravala, Hardik; Shah, Jay P.

doi:10.1016/j.protcy.2014.08.046

Cited by 31 publications

(14 citation statements)

References 5 publications

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“…Efforts have been made in the past to obtain high-quality defect-free castings by developing an in-depth understanding of the areas such as (a) design of runner and gating systems, 32–40 (b) design of feeding systems (locations and number of risers), 41–45 (c) filling and solidification during different casting processes, 46–50 (d) casting process parameters (thermo-physical data, injection parameters, etc. ), 50–54 (e) stress distribution in cast products, 55–59 and (f) quality control and assurance of the cast products.…”

Section: Case Studies Using Casting Simulation Toolsmentioning

confidence: 99%

Simulation tools in enhancing metal casting productivity and quality: A review

Khan

Sheikh

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Casting simulation softwares are increasingly being used in modern foundries and metal casting industries. Softwares simulate the casting process in a virtual domain and provide insight into mold filling, solidification and cooling, and casting defects. Casting simulations allow designers to model, verify, and validate the process followed by optimization of design and process parameters before they actually put into practice. This article aims at exploring the methods of modeling and simulation of metal casting processes with reference to some related case studies. Most commonly available casting simulation softwares and the underlying mathematical models used are briefly introduced. Casting process simulation together with the results obtained is well explained. Case studies from the literature revealed that simulation tools are playing a vital role in producing high-quality defect-free cast products by providing an in-depth understanding of mold filling and solidification, gating, runner and feeding system design, and other process parameters. Recent efforts on integrating the casting simulations to mechanical performance simulations are discussed which is quite promising in predicting the service life of cast products. It is concluded that simulations have been well established in metal casting processes and more developments in simulation tools are needed for reliability prediction of castings.

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Section: Case Studies Using Casting Simulation Toolsmentioning

confidence: 99%

Simulation tools in enhancing metal casting productivity and quality: A review

Khan

Sheikh

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…In the pre-production stage, flaws in castings such as shrinkages and micro porosity can be prevented by the simulation of filling and solidification. Adjustments to the gating and feeder systems, along with technological adjustment of casting and casting parameters by means of a computer simulation, can help to prevent such flaws [1][2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Optimization of a gating system by means of simulation software to eliminate cold shut defects in casting

Šabík

Futáš

Pribulová

et al. 2021

JCME

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The current trend in foundries is to achieve the production of high quality and competitive cast components. The innovation and optimization of current processes is a necessary element to achieve this goal. With the help of numerical simulations, it is possible to replace financially demanding and time-consuming experiments in real conditions with simulations that can reliably represent foundry process using computer technology. By a detailed analysis of the simulation results, we can predict various risks that could negatively affect the production process. This article monitors the influence of changes in the design of the gating system on the surface quality of a clutch wheel casting made of ductile iron, in the production of which two models of the gating system for casting were constructed in CAD software. Verification of gating systems was performed using the simulation software NovaFlow & Solid. The aim of the design change of the gating system is to reduce the amount of liquid metal used per casting, which can have a significant economic impact on industrial production. For this purpose, several simulations of the gating system of the casting were performed, while 2 which are the most representative for the mentioned problem were selected for the needs of the article. The main task of the simulation was to set the cellular network and conditions as close as possible to the reality of casting and the subsequent design and modification of the gating system.

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“…Jie et al (2014) used the Pro Cast software package to improve the aluminum alloys casting process, and they concluded that the increasing of the cast temperature and casting process speed solves the porosity problem [4]. Bhatt et al (2014) presented the design of feeding system of casting part and solidification simulation for cast iron by using AutoCast software [5]. Choudhari et al (2014) presented the design of a feeding system (feeder location, feeder shape and size, and feed aids) by using AutoCAST X numerical simulation software [6].…”

Section: Introductionmentioning

confidence: 99%

Application of CAD/CAE/CAM Systems in Permanent-Mold Casting Improvement

Dučić

Jovičić

Radiša³

et al. 2020

Teh. vjesn.

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This paper presents the application of CAD/CAE/CAM systems at the improvement of the manufacturing the flotation balls for grinding ore. Flotation balls need to satisfy the appropriate requirements in terms of dimensional, chemical, mechanical and physical properties. These properties are directly related to technology of ball manufacturing, in this case -permanent-mold casting technology. Software tolls from the group of CAD/CAE/CAM systems were used for designing the casting parts, casting and feeding systems, mold and simulation of permanent-mold casting process. Based on results of casting process simulation the casting process in real industrial conditions was realized. After the casting process, testing of casting parts has been performed. The testing gave satisfactory results, so the presented methodology, based on CAD/CAE/CAM systems, is acceptable for manufacturing program in foundry.

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Design Optimization of Feeding System and Solidification Simulation for Cast Iron

Cited by 31 publications

References 5 publications

Simulation tools in enhancing metal casting productivity and quality: A review

Simulation tools in enhancing metal casting productivity and quality: A review

Optimization of a gating system by means of simulation software to eliminate cold shut defects in casting

Application of CAD/CAE/CAM Systems in Permanent-Mold Casting Improvement

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