Abstract
M/s. Boparai Metals, a small scale industry situated in Industrial Area, Mohali, Punjab is manufacturing and supplying automotive and non automotive component to tractor companies in Punjab and aiming to provide the best solutions. The company is facing the problem of castings defects i.e. porosity, hot spot and shrinkage in cooler plate during the Sand Casting process. In this work, the study of existing process was done to find the root cause of the problem. Three dimensional gating system of cooler cover plate were modified by using UG– NX software. The models were imported using ADSTEFAN software for simulation of SAND-CASTING process. Based on the specification of cooler cover plate material, cast iron moulds in the green sands and input process parameters; design calculation of casting model was undertaken. Three case studies i.e. analysis based on the solidification method, were carried out for defect analysis of casting component and simulation study was done for process parameter optimization using ADSTEFAN software. It was observed that molten metal enters at critical location of cover plate causing turbulence in metal flow and solidification was not getting achieved in the directional way, thereby resulting in shrinkage defect. The shrinkage defect was removed by providing risers at proper location.
Highlights
Factors influencing mechanics of sand casting: The major factors which influences the mechanics of casting are: heating and pouring of metal, fluidity and its rate, solidification and cooling, Shrinkage, pouring time, pattern / mould design, casting attributes properties, air pressure and metal filling rate
Defects were eliminated by using casting simulation software ADSTEFAN
In order to perform the mould filling with solidification simulation of automotive part, the commercial ADSTEFAN software was used
Summary
Casting is more than 5000 years old process. It is mentioned in several Sanskrit works like Shilpashastra, Stahapatyaveda, Atharvaved etc. Equipments used in casting are mentioned the Rigveda. Like casting and pattern design, moulding procedure, melting and pouring of molten metal. Design considerations include promoting directional solidification when designing the mould (i.e. riser should be properly dimensioned and located), avoiding hot spots and ensuring easy pattern withdrawal
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callMore From: International Journal of Engineering and Advanced Technology
Disclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
