WITHDRAWN: Simulation for prediction analysis of defects in pulley casted using sand casting process

Sunanda, Adyana; Raju, M.

doi:10.1016/j.matpr.2021.01.734

Cited by 4 publications

(3 citation statements)

References 10 publications

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“…In pursuit of a robust mold design, it allows a shift from the conventional trial-and-error approach to a modern proof-of-concept approach which makes the process faster, more efficient and less expensive [2]. The simulation-based optimization is a relatively new idea for developing a robust mold design [3][4][5][6][7]. Demler et al used casting simulation software to determine suitable casting parameters and to predict porosity in components of a drive train made of low alloy steel [4].…”

Section: Introductionmentioning

confidence: 99%

“…It is reported that the defected casting rate dropped from 20% to 10% using simulation-based modified casting system. Sunanda et al studied the sand casting optimization of a medium carbon steel pulley using Procast software [6]. The main problem is a very heated central region of the pulley casting during solidification leading to hotspots and shrinkage porosity.…”

Section: Introductionmentioning

confidence: 99%

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Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments

Khan

Sheikh

Gasem

et al. 2022

Metals

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The quality and performance of steel castings is always a concern due to porosities formed during solidification of the melt. Nowadays, computational tools are playing a pivotal role in analyzing such defects, followed by their minimization through mold design optimization. Even if the castings are produced with defects in a permissible range, it is important to examine their service life and performance with those defects in a virtual domain using simulation software. This paper aims to develop a methodology with a similar idea of simulation-based optimization of mold design and predictions of life and reliability of components manufactured with minimized casting defects, especially porosities. The cast parts are standard fatigue specimens which are produced through an optimized multi-cavity mold. X-ray imaging is done to determine the soundness of cast parts. Experimental work includes load-controlled fatigue testing under fully reversed condition. The fatigue life of specimens is also simulated and compared with the experimental results. The classical strength-stress model is used to determine the reliability of cast parts through which a safe-load induced stress of steel castings is determined. Finally, probability distributions are fit to the reliability results to develop the reliability models. It is found that porosities can be minimized significantly in the mold design phase using casting simulations. Nevertheless, some porosities are bound to exist, which must be included in realistic estimation of fatigue life and reliability of cast parts.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments

Khan

Sheikh

Gasem

et al. 2022

Metals

View full text Add to dashboard Cite

show abstract

“…Another explanation about product defects resulted in the aluminium casting process [8]. Porosity defects can harm various applications, for example, on diesel engines [9], offshore construction applications [10], and engine components such as pulleys [11].…”

Section: Introductionmentioning

confidence: 99%

Secondary Material Casting of Al-Si for Making Handle Brake in Variation of Duct

Partono

Hidayat

Masyrukan

et al. 2022

KEM

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This study aims to determine the effect of the mold casting duct variations on shrinkage, porosity defects, density, hardness, and chemical composition of materials. The primary raw material uses melting secondary aluminium through a small-scale smelting furnace. Research study about three kinds of ducts: triangular duct, rectangular duct, and circular duct. The testing chemical composition uses an emission spectrometer. Research founds defects by comparing the dimensions of the original object with the specimen results of each duct variation. The density value calculates porosity defects. ASTM E10 standard Brinell test measures the hardness. Besides, ASTM E3 standard test quantifies the microstructure of the product. The highest average shrinkage is the triangular ducts at 3.68%. The least significant numbers of porosity were in rectangular ducts of 2.964 gr/ml. Higher the density value, the denser the material, and the more negligible the porosity. The density of the material affects the hardness material obtained from the results of the Brinell test. The hardness of the Brinell test brought that the rectangular duct with 102.5 BHN was the most enormous. In addition, the results showed that the chemical composition mainly contained mostly chemical elements (Al) 87.1% as the main chemical ingredient and (Si) 9.51%.

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Defects and remedies in casting processes: a combinatorial approach between manual and digital optimization technique for enhanced quality casting

Patwari,

Bhuiyan,

Noman

et al. 2024

Discov Mechanical Engineering

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WITHDRAWN: Simulation for prediction analysis of defects in pulley casted using sand casting process

Cited by 4 publications

References 10 publications

Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments

Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments

Secondary Material Casting of Al-Si for Making Handle Brake in Variation of Duct

Defects and remedies in casting processes: a combinatorial approach between manual and digital optimization technique for enhanced quality casting

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