Casting simulation and defect identification of geometry varied plates with experimental validation

Abstract

This work mainly deals with the simulation of geometry varied plates subjected to permanent mold gravity casting process. There are extensive demands of Aluminum and its alloys in diverse industries owing to its better properties especially mechanical (good strength and stiffness with low density). Aluminum alloy AlSi5Cu3 was chosen and the behavior of metal filling and solidification was examined using AUTOCAST – XI software equipped with flow plus module. Three rectangular plates with variation in thickness were selected as casting geometry with equal length and width. Three feeders have been applied to each cavity at various locations with optimized dimensions. The casting yield and casting quality were calculated for all casting geometry. The values of casting yield for 8 mm, 12 mm and 16 mm thick plates were 91.20%, 91.5% and 92.05% while casting quality were 95.20%, 94.05% and 93.68%, respectively. The temperature difference, the velocity of melted metal and solidification time were analyzed for thickness varied plates. The front velocity of the liquid metal was calculated and having values of 1.02 m/sec, 0.91 m/sec and 0.39 m/sec and solidification time was 23.56 sec, 31.56 sec and 37.35 sec for 8 mm, 12 mm and 16 mm thick plates, respectively. The cooling curves for different geometry were obtained by placing virtual thermocouple at various locations. Shrinkage porosity defect identified and validated with actual experimentation. The depth of shrinkage porosity was measured by simulation results and calculated for actual casted plates. It showed a variation of shrinkage porosity depth by 10%, 5.88% and 4.34% for 8 mm, 12 mm and 16 mm thick plates, respectively.