Design And Simulation Of LM 25 Sand Casting For Defect Minimization

Abstract

The most critical step in casting process is the solidification of molten metal in prepared mould cavity, because this is time where the defects like volumetric shrinkage, porosity, blowholes occurs and affects the quality of casting. These defects come into picture when the part is completely manufactured and went for testing. In traditional casting process to overcome these defects, again we have to redesign feeder, gating system, etc, and repeat the casting, so this will directly affect the rate of production. If these defects can be address before casting then it will really help casting industry to improve their production rate and revenue. These problems can be address using smart methoding and advance simulation using casting software. In this paper the study has been made to improve design and manufacture a defect free casting in particular volumetric shrinkage defect and yield. The part taken for study is Contact wheel from one of casting company in Aurangabad, Maharashtra. The company suffers from casting defects like shrinkage, blowhole and pinhole. Casting solidification is quickly simulated to view the progress of cooling from casting surface to interior, and to predict the location of shrinkage defects such as porosity and cracks .This helps in verifying and optimizing the design of feeders, which can be verified by advanced simulation. This simulation result was compared with the experimental trial and the comparison result was found to be good.