Evolution of microstructure and hardness in shell moulded impeller casting

Abstract

ABSTRACT To remain competitive in this growing field of the manufacturing industry, there is a need to reduce the lead times in the development of a component. The virtual simulation environment tool can be utilised for minimising production time as well as assure defect-free casting. This technique is based on heat transfer and volumetric calculations for prediction of possible defects. In this paper, analysis of automobile impeller casting is explored. The modelling of the casting and feeding system is done using the CATIA software. The CAD model of the impeller is imported into the simulation environment for solidification simulation. The simulation is performed using SolidCAST software which is based on the Finite Difference Method. The simulations are performed to ensure proper feeding for achieving sound casting. The melting trials are performed in jobbing foundry. The hardness and microstructure analysis of simulated and experimental casting is performed so as to correlate. The section thickness and cooling rates in casting were analysed and used for formulating hardness and microstructure in the experimental castings. The statistical predictions based on simulated and experimental results are presented for formulating Brinell hardness and amount of pearlite phase in particular section of shell moulded ductile iron casting.