Numerical and experimental approach to eliminate defects in al alloy pump- crank case processed through gravity die casting route

Abstract

A numerical investigation was carried out with the help of computer based casting simulation software to eliminate defects such as shrinkage due to solidification, cracks, imperfect mould cavities and riser level issues. This investigation also helps to improvise the casting process done by gravity method in aluminium based alloys. The defects mentioned above are occurring in the castings due to wrong choice in selecting the process variables or gating and riser design. In this investigation, MAGMASOFT software was used for simulate the casting process undergoing solidification. The results from the simulation shows the possible areas which may be subjected to defects or any other malfunction. Before entertaining the simulation software, few castings were manufactured by making alterations in the process variables and the same castings were modeled and tested using the software. Then, using the MAGMAsoft software, simulations were carried out by modifying the position of the core pins and making possible design changes in the casting component without compromising its design intention. The simulation results showed that, the design changes helped in reducing the casting defects of the centrifugal pump crank case. Based on the simulation result, the castings were produced and checked for the defects. The casting obtained as per the modifications done based on the simulation result showed zero defects.