Simulation of casting process: case study on the gating and feeding design for outlet diaphragms of iron ore ball mill

Abstract

In this paper, the sand casting process was evaluated using ProCAST simulating software and practical experience for manufacturing of the high chromium stainless steel outlet diaphragms used in iron ore ball mill. In the simulation practice, the effects of feeding and gating designs on the liquid flow, heat transfer and solidification phenomenon were evaluated to minimize the liquid surface turbulence during filling of the mold cavity and the shrinkage porosity formation during the liquid solidification in the mold. The effects of different gating ratios and number of feeders were numerically studied using different indicators in the software such as linear velocity, niyama criteria, fraction solid and shrinkage porosity. Further, the optimal design obtained by simulating process was empirically examined. The simulation results showed that the 1:3:4 gating ratio is the proper gating system that it obtains an unpressurized fluid flow without any surface turbulent of the liquid steel in the filling step. In addition, the simulation of solidification phenomenon was indicated that four feeders are required to eliminate of the shrinkage porosities. The empirical casting examination shown the optimal design by the simulation is proper for manufacturing of the steel part without critical defects.