Casting Industry Research Articles

Lean Implementation Framework: A Case of Performance Improvement of Casting Process

Globalization breeds increasing competition. In today’s dynamic climate, lean thinking has been found a promising business continuous improvement strategy for improving quality while reducing product cost and delivery time. However, its implementation has dynamic nature of challenges that varies from industry to industry and country to country, necessitating a specific framework by taking all stakeholders onboard. This study aims to propose a lean implementation framework to reduce defects and waste to improve the performance of the metal casting industry. The structure of the framework has been divided into three phases namely the lean conception phase, lean implementation phase, and lean sustainability phase. The proposed framework integrates the six sigma DMAIC methodology with lean tools and techniques to reduce defects and achieve performance improvement. A solid cast software has been used as a computer-assisted casting simulation tool to perform the analysis of defects within the casting. Further, the proposed framework is demonstrated and validated by employing a real-time case study that was manufactured using the sand casting process. The obtained results show remarkable improvements in poured metal weight (33.3%), mold weight including gating system (40%), casting yield (24.56%, rejection rate (90%), and financial saving (24.63%). As a result of analysis of percentage improvements data, the proposed framework can provide the practitioners with a standard roadmap and motivate the casting industries to implement lean for performance improvement through organizational change. Through the effective application of the lean implementation framework, quality enhancement has been demonstrated.

Fault Identification in Investment Casting Process Using Naive Bayes Method

Optimization in the investment casting industry is a difficult task as it contains multiple-stage operations for pro- duction. Although taking care of all the parameters investment casting industry is facing issues due to defects in the final product. This leads to a decrease in production, loss of production resources, and efficiency by analyzing the parameters and defects from the previous batches. We can predict the occurrence of defects for the given batch using a suitable machine learning technique. The Naive Bayes method, a supervised machine learning technique, is introduced to predict defects for the given batch from the model developed for it. Naive Bayes method includes four different models as, Gaussian NB, Multinomial NB, Complement NB, Bernoulli NB. This paper compared results for each model and analyzes which Naive Bayes model is best suitable for the Investment Casting industry and can predict the defect in the final product before it occurs.

Development of steel wheel detail casting technology

The article presents the problems encountered in the casting of wheel parts and their modern solutions. It is known that wheel-shaped parts are made from carbon steel by pressure treatment; therefore, their casting is considered one of the latest achievements of the casting industry.

Resilience and sturdiness of the foundry sand as a result of the partial substitution of cement and fine aggregate

Foundry sand is a superior quality silica sand byproduct of the refractories metal casting industries. Because of its great heat conductivity, it has been utilised as a moulding casting material for millennia. Raw sand is utilised in a variety of foundry procedures, and different binders and admixtures are applied to it to improve its characteristics. For the foundry sector, experiment sand is no longer acceptable. The goal of this experiment is to determine the chemical characteristics of foundry sand, as well as the optimal replacement ratios for foundry sand as a fine aggregate: 10%, 20%, 30%, and 40%. For self-compaction, a super plasticizer is also added. Finally, the strength characteristics of foundry sand-formed concrete are identified. The experiment aims to provide the same strength as regular concrete. Experimentation leads to the research of beam strength characteristics. Experimentation leads to further study of concrete's pesticide and mechanical characteristics. The strength properties like compressive strength, split tensile and flexural strength is improved upto -%,-% and % for 20% substitution of foundry sand added mix. The better performance were observed at early ages of curing. The resistance against acid attack will be allowable upto 20% substitution of foundry sand. The usage of foundry sand will be eco-friendly and scalable for product making in products.

Rapid Manufacturing of Die-casting Tools - a Case Study

Additive manufacturing evolves as a viable manufacturing process for making a multitude of products. The motivation for this paper is to explore the competitiveness of additive manufacturing in making die tools for casting aluminium parts compared to more traditional machining approaches. Thus, the main objective of this study is to analyze additive manufacturing as a competitive advantage for SMEs (Small and Medium Enterprise) within the aluminium casting industry. Today, additive manufacturing is mostly used for producing customized high value products where price sensitivity is low. Literature reports that additive manufacturing mainly has been used where the costs of production is limited to a small number of parts compared to traditional manufacturing. Data is collected from a SME case study, where data on cost, time and quality is assembled to compare the different routes of additive and traditional approaches. Results show that product quality improves and that time to market is significantly reduced by having in-house additive manufacturing capacity and capability.

SMEs’ financial risks in supply chain trade with large companies: The case of Italian automotive component industry

Becoming a supplier of large companies is traditionally considered to be positive for small and medium enterprises’ (SMEs) competitiveness. Small businesses can take several advantages by joining supply chain trade with large companies such as scale efficiency and productivity as well as technological and managerial abilities, product and process innovation, market positioning, and reputation. However, not everything is convenient per se. The subcontracting by large companies might provide some financial criticalities that need to be faced and properly managed by SMEs to exploit supply chain benefits without affecting financial stability and losing competitiveness. In this direction, the literature on supply chain finance has recently focused on financial issues related to working capital optimization in terms of accounts payable, receivable, and inventories. Adopting this perspective, the study contributes to a better understanding of SMEs’ financial constraints in supply chains driven by large companies by investigating a sample of small Italian firms, which operate in the metal casting industry and by comparing firms joining and not joining the automotive supply chain.

Optimal resource scheduling for SMEs using cloud in manufacturing sectors

Defining on a common policy which effectively suits all the production units, stakeholders and suppliers is very difficult to figure-out in highly populated countries like India. Manufacturing industries are ineffective in managing services, this is due to the communication gap between stakeholders. Approximately 48 million small and medium businesses are registered in India, according to a report by the Ministry of Micro, Small and Medium Enterprises (MSME). Among these numbers, SMEstend to contribute 40% of the total exports to India's industrial output, which is nearly 45%. As scheduling process majorly impacts on the time and cost of job completion, it is a critical part of the project. To efficiently schedule resources related to the casting industry, we propose a hybrid Ant Colony Optimization strategy. The efficiency of this enhanced algorithm was simulated to verify its effectiveness and the results show that, the proposed model minimizes both cost and time. It also maintains workload balance to maintain optimum resource utilization.

Durability performance of self‐compacting concrete made with waste foundry sand

AbstractThe utilization of waste foundry sand (WFS) has been widely explored in conventional concrete to evaluate strength and durability properties. In this study, durability properties of self‐compacting concrete (SCC) made with various percentages (0%–30%) of WFS as a partial replacement of river sand up to the age of 365 days are investigated. Annually, more than 60 million metric tons of WFS is produced worldwide from the casting industry, creating environmental problems. The scarcity of river sand is another major area of concern that can be addressed with the utilization of WFS in concrete. Tests were conducted for fresh properties, compressive strength, water absorption, sorptivity, rapid chloride permeability, and sulfate resistance. All the SCC mixes exhibited fresh‐state properties as per EFNARC. With the incorporation of WFS up to 30% increased volume of permeable pore space (13.43%–16.67%), water absorption (2.11–3.07 mm), chloride permeability (2119–3553 C), and decreased compressive strength of sulfate‐cured samples by nearly 5% compared to water‐cured samples at 28 days of curing were observed. The concrete samples showed better performance of pore structure, permeation, sulfate attack, and chloride permeability at 90 and 365 days of curing age. It was found that cost‐effective SCC with performance comparable to the control mix could be achieved by using WFS up to 10%.

Toughening of Ceramic Shell Mould with Rice Husk Fiber (CSm-RH) to Improve Strength Property and Mould Performance

For ages, ceramic shell mould (CSm) have been extensively applied in investment casting industry. The formation of CSm requires multiple steps of dipping, layering drying and firing stages. The later steps are very crucial as the solidification thin layer CSm that consist of loose ceramic particles easily cracks when exposed to the higher thermal effect. The inclusion of fiber or any reinforces phases is able to enhance fired ceramic body and also strengthen the green ceramic structure. Thus, the feasibility of rougher NaOH treated rice husk fiber (RHT) prior embedded into composited structure has shown a significant CSm improvement by induced a better adhesion properties and larger bonding area with brittle ceramic matrix, resulted in increased green strength (1.34 MPa) and fired body strength (4.32 MPa). Owing to the decomposed of lignin layer in CSm with untreated rice husk fiber (CSm-RHU) exhibited a higher porosity that provide a better permeation paths of air flow during molten metal pouring as increased 30 % from the standard CSm permeability, giving an enormous benefit for investment casting cooling process. Overall, the incorporation of RHT fiber in a CSm matrix of both green and fired body governed in toughening of brittle ceramic body, hence avoid failure to the casting mould.

Layout Design and Die Casting Using CAE Simulation for Household Appliances

Due to the development and industrialization of science and technology, aluminum alloys have been developed in various fields. Recently, the government has been pursuing ways to decrease the weight and increase the recyclability of various components in order to conserve resources, energy, and the environmental. In keeping with this trend, cast iron products are being replaced by aluminum products in the foundry industry by using high-pressure die casting (HPDC). Casting layout design, relies on the experience and knowledge of mold designers in the casting industry, which proves insufficient to respond to the rapidly changing needs of the era and to increasing production costs. Designing and producing casting layouts using CAD/CAM/CAE technology has become a critical issue. Computer-Aided Engineering (CAE) technology is rapidly increasing with the development of computer software and hardware. CAE technology not only predicts defects in mass production but also performs filling or solidification analysis during the mold design stage before production, enabling optimal mold design methods. New technologies that combine the emerging casting processes of filling and solidification analysis using computer simulation with existing technology and practical experience in the field are rapidly increasing in the foundry industry. Based on empirical knowledge, the layout and design of casting products has traditionally progressed through trial and error. The solutions achieved through scientific calculation and analysis using CAE technology can save a great deal of money and time in the building of die-casting molds and in their design and fabrication. In this study, numerical analysis of household appliances (cooking grills) quickly and accurately predicts problems arising from the filling and solidification of the melted metal in the casting process, thereby ensuring the quality of the final cast product. These results can be used to quickly establish a sound casting layout with reduced production costs.

X-ray Computed Tomography Studies on Porosity Distribution in Vacuum Induction Cast Al-7Si Alloys

Porosity in aluminum alloys is a great concern to the casting and automotive industry. In this publication, porosity formation in air-melted and vacuum induction melted (VIM) aluminum alloys was studied and compared to understand its effect on microstructure and mechanical properties of Al-7Si alloys. Al-7Si alloys were cast at 700°C and 900°C in a muffle furnace and VIM furnace. Microstructural results show that the alloys cast in muffle furnace refined the eutectic silicon compared with the cast samples prepared in VIM furnace. X-ray computed tomography (XCT) was used for three-dimensional (3D) visualization and quantification of porosity in these alloys. The volume fraction of pores was observed to be higher in alloy air-melted at 900°C compared with 700°C. XCT results from VIM alloy samples showed no significant porosity when cast at either 700°C or 900°C. The morphology of large pores in alloys air-melted at 700°C represents the formation of shrinkage porosity due to the incomplete flow of molten metal during solidification. Tensile test results show that the elongation property of VIM alloy was increased by more than 20% compared with air-melted alloy. The tensile strength and elongation were observed to be higher for alloy samples cast at 700°C compared with 900°C for both air-melted and VIM alloys. The findings from microstructure, XCT, and tensile tests show that vacuum induction melting improves the mechanical properties of the alloy compared with air-melted alloy.

External Surface Quality of the Graphite Crystallizer as a Factor Influencing the Temperature of the Continuous Casting Process of ETP Grade Copper.

Today’s world is a place where lack of electrical energy would be unimaginable for most of society. All the conductors in the world, both aluminum and copper, have their origin in various types of casting lines where the liquid metal after crystallization is being processed into the form of wires and microwires. However, the efficiency of the continuous casting processes of metals and the final quality of the manufactured product strictly depend on the design of the used crystallizers, the materials used during its production and its quality. Research conducted in this paper focuses on the latter, i.e., external surface quality of the graphite crystallizer at the place of contact with the primary cooling system. In order to quantify its influence on the continuous casting process numerical analyses using the finite element method has been conducted, which results have been further confirmed during empirical tests in laboratory conditions. It has been proven with all of the proposed methods that the temperature of the obtained cast rod is closely linked to the aforementioned surface quality, as when its roughness coefficient surpasses a certain value the temperature of the obtained product increases almost twofold from approx. 150–170 °C to 300–320 °C. These values might influence the quality and final properties of the cast rod, the susceptibility to wire drawing process and possible formation of wire drawing defects and therefore be of much importance to the casting and processing industry.

Process optimization by value Stream Mapping

Value Stream Mapping is the great tool of revealing waste in the manufacturing units, streamlining the production processes by recognizing and removing the steps which will not add the value to the process of producing the products. A flow chart reflects the process is created to get the current state of the operation steps. Waste of time and resources in each step of process are to be found which reflects the activities of not adding value to the processes. Simulation software is to use to reduce and simplify to the minimal number of steps necessaries to carry out the process. By clearing the activities which will not add any value to the process, the weightage of value added time in the entire process increases and process speed improves. This will help the reconstructed flow makes process line more efficient and productive. This paper elaborates about the right steps for eradicating the activities which are not adding value to the processes in the casting industry with the help of simulation software. The rearranged process flow diagram in its future state with process steps and information, simplified and made less expensive and enhance in productivity by optimizing the process optimization.

Numerical Investigation of the Combined Effect of Reactive Cleaning and Active Filtration on Inclusion Removal in an Induction Crucible Furnace

Herein, the combined influence of reactive cleaning and active filtration on inclusion removal is investigated using numerical simulations. Carbon‐bonded ceramic foam filters with active and reactive effect are inserted into the steel melt to remove nonmetallic inclusions. In case of reactive cleaning, carbon can dissolve from the filters into the melt. As a result, carbon reacts with oxygen on inclusion surface to form carbon monoxide bubbles. The filters can capture inclusions in terms of its active effect. A numerical model is developed in the open source library OpenFOAM to study the efficiency of the combined effect of filters. The results of the numerical simulations show that the flow field and the concentration of carbon are affected considerably by the position and the number of the used filters. Moreover, the results highlight the significant positive effect of reactive cleaning on the level of melt cleanliness despite the short time of the reactive phase of the filters. Moreover, it is apparent from the results that reactive cleaning dominates active filtration. The findings of the article prove the importance of reactive cleaning in the steel casting industry to enhance inclusion removal and improve steel quality.

Evaluation of Mechanical and Wear Roperties of AA2024 Through Co2 Casting Using Silica Sand

Silica sand is generally used moulding sand in the casting industries and majority of the castings produced worldwide because of its easy availability and binding properties. In the present study, silica sand is taken as moulding material and studies the effect of different shapes on the mechanical and wear properties, micro hardnessand wear tests. For this casting the selected material (AA2024) into two different shapes (cube and cylinder) using silica sand as the moulding material and study the effect of split piece pattern on the properties and wear of the casted components. Co2 casting is chosen as the industrial process and study mainly focused on to produce the defect free surfaces on AA2024 with split piece pattern which is difficult to control. Destructive tests like hardness, surface roughness are conducted and wear properties of the components is also observed. It is observed from the results that cylinder component has higher hardness due to the faster cooling rate, lower surface roughness and lower wear rate. Analysis concluded that Co2 process is better working for the cylinder type of objects.

Experiment analysis the effect of different parameters during slot cutting by using Taguchi technique identified tool wear behavior

In recent decade’s machine tools and cutting tool technology, (EDM) is utmost trending techniques for making factual shape on different material like HSLA, H11, H-13 etc. steels and is maximum endorsed techniques to be ensure for mold & die making. In Electric discharge machining process increases the mechanical and physical properties when used with powder suspension and with assertive composite of electrode materials. Result analysis through the effect of parameters and their level of practically examined least number of experiments trail by during slot cutting by using Taguchi technique identified tool wear. Now a day’s most prominent materials which are largely used in die making & mold casting industries like HSLA, H11 die steel. In the latent research M.R.R and T.W.R examined through the result analysis by the taugchi techniques changes in the level of the selected parameters. Selected parameters like electric current, pulses-on time, graphite and tungsten powders imposed in dielectric by changes the range of different levels with or with-out using magnetic fields. To find out the better result of analysis we followed the ANOVA techniques to optimize and the effects of the parameters at optimum level/range for the M.R.R and T.W.R of the cooper tool.

Experimental Verification of Real-Time Flow-Rate Estimations in a Tilting-Ladle-Type Automatic Pouring Machine

This paper discusses a real-time flow-rate estimation method for a tilting-ladle-type automatic pouring machine used in the casting industry. In most pouring machines, molten metal is poured into a mold by tilting the ladle. Precise pouring is required to improve productivity and ensure a safe pouring process. To achieve precise pouring, it is important to control the flow rate of the liquid outflow from the ladle. However, due to the high temperature of molten metal, directly measuring the flow rate to devise flow-rate feedback control is difficult. To solve this problem, specific flow-rate estimation methods have been developed. In the previous study by present authors, a simplified flow-rate estimation method was proposed, in which Kalman filters were decentralized to motor systems and the pouring process for implementing into the industrial controller of an automatic pouring machine used a complicatedly shaped ladle. The effectiveness of this flow rate estimation was verified in the experiment with the ideal condition. In the present study, the appropriateness of the real-time flow-rate estimation by decentralization of Kalman filters is verified by comparing it with two other types of existing real-time flow-rate estimations, i.e., time derivatives of the weight of the outflow liquid measured by the load cell and the liquid volume in the ladle measured by a visible camera. We especially confirmed the estimation errors of the candidate real-time flow-rate estimations in the experiments with the uncertainty of the model parameters. These flow-rate estimation methods were applied to a laboratory-type automatic pouring machine to verify their performance.

Effect of industrial waste on the behaviour of expansive soil

The expansive soil has serious impact due to its unstable volumetric behaviour when it undergoes seasonal variations. In order to utilise the problematic expansive soil for any kind of work it needs to alter the behaviour of soil by stabilisation using addition of admixtures. From the economical point of view using industrial waste materials is the cost-effective technique. In this work the selection of industrial waste materials which comes from tile manufacturing such as Tile Waste Powder (TWP) and Foundry Sand (FS) outcome of metal casting industries as an admixture. The Tiles Waste Powder has the nature to improve the compaction behaviour of expansive soil because of its high lime content and Foundry sand are used to develop the strength behaviour of problematic soil due to the presence rich silica content.In this paper, untreated soil got treated using the different proportions such as 5,10, 15,20 and 25% of Tile waste powder and their corresponding the compaction and strength characteristics of the soil sample were determined under different curing periods. Also the tests have been conducted for optimum percentage of tile waste mixed along with varying percentage of Foundry Sand (4, 6, 8, 10 and 12%) in soil sample. The results was obtained from the standard proctor test, UCC and CBR test and it further analysis shows that the increasing the proportion of TWP rises the peak strength of the treated soil up to 20% for the maximum 28 days curing. Also, from the result analysis for the combination of FS and TWP by optimum percentage of Tiles Waste Powder (20%) with 12% of Foundry sand shows the increment in the strength characteristics of soil. The TWP and Foundry Sand can be effectively used in stabilization works in order to utilise the waste by effective minimization of disposal problems.

Investigate Temperature Preheating on the Chill Plate to Identify Surface Characteristic on the Ductile Iron by Sand Casting

The chilled casting method is widely used in the metal casting industry to accelerate the mold's cooling rate. This method is very suitable for surface hardening by depositing the elements contained in the chill material onto the surface of the object being cast. One of the factors that influence surface hardness characteristics is the diffusion temperature. This study aims to determine the microhardness, surface layer thickness, and the element contained on the surface. The main material produced into Y-Block is ductile cast iron, the chill material is SS 304 plate with a thickness of 0.2mm. However, before the liquid material is poured into a mold, the chill plate is inserted into the surface of the pattern in the mold, then the plate was preheated. The result showed that the highest preheating temperature has produced microstructure around the surface area namely eutectic carbide of (FeCr)7C3, and (FeCr)3C. SEM-EDX analysis shows that 7.13%Cr is contained on the coating layer at a thickness of 0.020 mm and an average hardness of 700-900 HV.

Mediation of lubricated air films using spatially periodic dielectrophoretic effect

A stone thrown in a lake captures air as it collides with water and sinks; likewise a rain drop falling on a flat surface traps air bubbles underneath and creates a spectacular splash. These natural occurrences, from bubble entrapment to liquid ejection, happen as air fails to escape from the closing gap between liquid and solid surfaces. Trapping of air is devastating for casting, coating, painting, and printing industries, or those intolerant of water entry noise. Attempts to eliminate the interfering air rely on either reducing the ambient pressure or modifying the solid surfaces. The former approach is inflexible in its implementation, while the latter one is inherently limited by the wetting speed of liquid or the draining capacity of air passages created on the solid. Here, we present a “divide and conquer” approach to split the thin air gap into tunnels and subsequently squeeze air out from the tunnels against its viscous resistance using spatially periodic dielectrophoretic force. We confirm the working principles by demonstrating suppression of both bubble entrapment and splash upon impacts of droplets on solid surfaces.