Volume 6, Issue 6, December 2018, Page: 150-160
Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation
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
Received: Sep. 13, 2018;       Accepted: Nov. 2, 2018;       Published: Jan. 28, 2019
DOI: 10.11648/j.ijmea.20180606.12      View  29      Downloads  52
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.
Keywords
Shrinkage Porosity, Improper Solidification, Air Entrapment, Mould Erosion, Click2cast
To cite this article
Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das, Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation, International Journal of Mechanical Engineering and Applications. Vol. 6, No. 6, 2018, pp. 150-160. doi: 10.11648/j.ijmea.20180606.12
Copyright
Copyright © 2018 Authors retain the copyright of this article.
This article is an open access article distributed under the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0/) which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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