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30 articles for “Casting Simulation”
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Lean Production using Casting Simulation to Promote FTR Approach
Abstract: When the talk is about the green production, then intention is to develop a product with first-time-right approach. Foundry desperately needs such production system, as it provides wide range of products. Even the small errors in the inputs (concept, design, raw material, process, etc.) can lead to wasted outputs [1], and invite unwanted cost of reworking. Thus, it is of extreme importance to develop the castings with FTR (first time …
Published in Journal of Production Research & Management · Vol. 3, Issue 2, 2013 · pp. 23–29 Read article
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Modification of gating System of Ball Valve Component using Soft-cast Simulation
Abstract: There are two main important considerations in castings are quality of the casting and yielding of the casting due to which scrape of material will reduce. Production of good quality casting mainly depends upon the gating system. In casting process gating and risering system has direct effect on its quality. Generally, many industries follow the trial and error method for casting process which is not economical for foundries for long …
Published in Trends in Mechanical Engineering & Technology · Vol. 7, Issue 3, 2017 · pp. 79–85 Read article
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Casting Simulation using ProCast: A Review
Abstract: Productivity improvement is the need of current market and manufacturing sector globally. In India the manufacturing sector is concentrated towards the casting process and majority of the products are manufactured by casting process. Various factors and parameters affect the quality and productivity of the casting process. Due to variation in these parameters various types of defects and shortcomings come to the scene during the casting process. In this review paper …
Published in Journal of Production Research & Management · Vol. 6, Issue 1, 2016 · pp. 1–8 Read article
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Casting Through Simulation- A Review
Abstract: In today’s competitive environment every foundry industries requires minimum rejection of component; rejection is caused by undesired uncertainty found in component’s it can be shrinkage cavity, sand inclusion, cold shuts etc. Reduce defect probability we need better setup and proper process control parameters without shop floor trials. Therefore industries develops many software packages for simulation of casting process it shows the virtual view like mould filling, solidification, cooling meanwhile it …
Published in Trends in Mechanical Engineering & Technology · Vol. 8, Issue 3, 2018 · pp. 12–17 Read article
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A Review Paper on Minimisation of Sand Casting Defects through Quality Improvement Methods
Abstract: Casting is a process of producing near net–shape metal components. It requires detailed planning, execution and quality inspection to ensure not only the dimensional accuracy of casting parts but the metallurgical integrity and mechanical properties of castings. This paper reviews the different types of casting defects such as shrinkage porosity, cold shut, sand inclusions, mould failure, surface hardening occurring in foundries. These defects directly affect on profitability and quality level …
Published in Journal of Thin Films, Coating Science Technology & Application · Vol. 4, Issue 3, 2017 · pp. 10–17 Read article
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Reduction of Shrinkage-Porosity Defects in Sand Casting Using Finite Element Analysis: A Review
Abstract: Today production of casting is easy but market requirement is quality casting. Earlier casting is made with large no. of defects due to large no. of process parameter in casting process. Specially, to predict phase transformation is very critical. As the problem of automation in process, shortage of skill labour now a days; casting simulation requirement is high and it is identifies defects earlier without making actual casting. This process …
Published in Journal of Materials & Metallurgical Engineering · Vol. 6, Issue 1, 2016 · pp. 1–5 Read article
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Autonomous Optimization, Method Design of Casting and Its Experimental Validation: A Case Study
Abstract: The metal casting is a complicated but a mass production manufacturing technique. But on the otherhand, the chances of casting rejection are also more if proper attention is not made at every stage ofcasting production. In the metal casting process, higher yield and minimum defects level are expectedby the foundry industries. In the present global and competitive world metal casting industries needsto perform efficiently with a reduction in rejections. This …
Published in Trends in Machine design · Vol. 8, Issue 1, 2021 · pp. 1–10 Read article
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Simulation and Analysis to Reduce the Shrinkage Defect in Sand Casting for the Rotor: A Review
Abstract: Casting is a process in which the metal is melted and poured into mold and allows it to solidify to get desired shape. Objective of investigation is to review on simulation and analysis to reduce the shrinkage defect in sand casting. In ductile iron casting, shrinkage defect is common. It is generally seen at the last solidifying area of casting. Other parameters like getting system, feeder, metallurgy of material, part …
Published in Journal of Production Research & Management · Vol. 7, Issue 3, 2017 · pp. 23–26 Read article
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A Review on Pressure Die Casting Technology and Recent Developments in Die Design
Abstract: A high production rate and cost effective method primarily used in the production of non-ferrous castings is the Pressure Die Casting (PDC) technology. It is widely used in the manufacturing of automobile components of complex geometry and intricate forms and shapes that may be difficult to produce by the other conventional casting processes. This paper gives an insight into the types of pressure die casting techniques. It also describes the …
Published in Trends in Mechanical Engineering & Technology · Vol. 8, Issue 2, 2018 · pp. 85–99 Read article
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Application of E-Foundry Based Simulation for the Development of Gating System Design for Endshield FG200 Casting
Abstract: Every casting, by virtue of its geometry, shape, basic material, composition and process has an optimal method. Casting should be designed to achieve controlled progressive directional solidification so that it becomes free from solidification related defects particularly shrinkage porosity. In this research project, endshield FG200 grey casting is being simulated using efoundry for the development of new gating system design. This new gating system ensures directional solidification in casting, thus …
Published in Journal of Mechatronics and Automation · Vol. 4, Issue 3, 2017 · pp. 8–17 Read article
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Characterization of Fracture Toughness of As-Cast Si-Mo- Cr Ductile Cast Iron
Abstract: In the present study, a Si-Mo-Cr ductile cast iron is developed by taking three different combinations, viz. Heat-1, Heat-2 and Heat-3 of the selective amount of silicon, molybdenum, copper and chromium. For fracture toughness characterization, the specimens are prepared from the samples in "as-cast" conditions. The value of static fracture toughness obtained from the experiments for the specimen of Heat-2 with a fatigue pre-crack is 54.49 MPa√ , whereas, for …
Published in Journal of Polymer & Composites Read article
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Solidification Curve Analysis of Cylindrical Casting by FEM
Abstract: In casting process, molten metal is solidified in mould cavity. Solidification process majorly classify into three different sections: (i) liquefaction (ii) solidify (iii) after solidification. In all three processes, one parameter which is called 'IHTC' (Intermediate Heat Transfer Coefficient), is varies with time. IHTC coefficient depends on shape, size, type of casting etc., so, it is continuously varies with all dependent functions. So, establishment of IHTC value is a very …
Published in Journal of Materials & Metallurgical Engineering · Vol. 6, Issue 3, 2016 · pp. 44–49 Read article
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A Review: Advancements and Applications of Investment Casting Technology in Aerospace Industries
Abstract: A conventional method for producing intricate and superior metal components is investment casting. It utilizes a wax pattern, a refractory shell, and molten metal to create a near-net-shape product. This method has been around for more than 5,000 years and is still relevant in various industries today, especially in aerospace. Investment casting, also known as lost-wax casting, is essential to the aerospace industry's ability to produce complex, high-performance parts. The …
Published in Journal of Materials & Metallurgical Engineering · Vol. 15, Issue 1, 2025 · pp. 61–66 Read article
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Development of Aluminium Based Silicon Carbide Particulate Metal Matrix Composite for Cylinder Liner
Abstract: Cylinder liner is used in engine block to give a wear protective surface for piston and piston rings. Friction accounts for a loss of over 30% of the total vehicle power. Over half of that power loss can be attributed to the frictional loss between piston rings and cylinder bores. The best approach for improving power train efficiency is to reduce friction loss and the way for reducing the rolling …
Published in Journal of Materials & Metallurgical Engineering · Vol. 7, Issue 1, 2017 · pp. 17–29 Read article
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Effect of Mould Cavity Thickness on Cooling Rate of Aluminium with Temperature Dependent Properties
Abstract: Solidification study of aluminium with temperature dependent thermal properties has been conducted. Effect of the mould cavity wall thickness on the cooling rate has been the target in the present work. Casting is earliest metal shaping process and has been used in many industries and households. Solidification during casting is the most crucial event which has been studied by the many researchers because it affects the quality of the casting …
Published in Journal of Thin Films, Coating Science Technology & Application · Vol. 3, Issue 1, 2016 · pp. 31–35 Read article
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Simulation and Experimental Analysis of Abuse Testing for Prediction of Life Cycle for Lithium Ion Battery Cell and Pack Level
Abstract: Lithium-ion batteries play a crucial role in contemporary technology, serving as the power source for everything from consumer gadgets to electric vehicles. However, their safety and longevity are significant influenced by the reperformance under extreme conditions, commonly referred to as ab use testing .This paper explores the simulation and analysis of ab use testing and life cycle prediction for lithium-ion batteries at both the cell and pack levels. Abuse testing …
Published in International Journal of Mechanical Dynamics and Systems Analysis · Vol. 2, Issue 2, 2024 · pp. 1–24 Read article
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Implementing Smart Voting Systems: Challenges and Opportunities
Abstract: This article offers a detailed explanation of the process for creating an innovative electronic voting system that utilizes the flexibility and efficiency of the Raspberry Pi. This method aims to improve voting security, transparency, and user-friendliness by employing digital technology and a mechanism called the Voter Verified Paper Audit Trail (VVPAT). The proposed system comprises several components, including a Raspberry Pi for control, candidate selection buttons, a camera for voter …
Published in Journal of Microelectronics and Solid State Devices · Vol. 11, Issue 2, 2024 Read article
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Sand Casting Process Optimization via Design of Experiments: A Review
Abstract: Designing and optimizing of gating is an essential part of casting foundry as it contributes significantly to predict and minimize the flow turbulence resulting to casting defects like rough surface, sand inclusion, etc. An Optimization scheme for gating design parameters for casting was proposed with different past studies of the researches. Various designs were modeled and mould filling simulation rooted to minimize turbulence and macro defects are recommended in this …
Published in Trends in Machine design · Vol. 4, Issue 3, 2017 · pp. 1–4 Read article
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Design and Analysis of Common Injection Mould for Variable Length of Extended Prob Housing Component
Abstract: The present study focused on designing a common injection mould for variable length of component of nylon material for prob housing plastic part and die material as H13. It was operated on 210 t vertical injection moulding machine. The type of cooling system employed wasline cooling. The effect of cooling system location on the stresses produced in the mould was analyzed and component defects determined by mould flow simulation. Injection …
Published in Trends in Mechanical Engineering & Technology · Vol. 11, Issue 2, 2021 · pp. 1–9 Read article
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Design and Manufacturing of Suspension and Steering System of a F3 Vehicle
Abstract: The suspension and steering systems are critical subsystems of any formula-style racing vehicle, directly influencing its stability, handling, and driver safety. This paper focuses on the design, analysis, and manufacturing of suspension and steering systems for a Formula Student F3 vehicle. The primary objective is to develop a lightweight, reliable, and efficient design that complies with Formula Student competition rulebooks while ensuring optimum ride quality and performance. Using advanced computer-aided …
Published in Trends in Mechanical Engineering & Technology · Vol. 15, Issue 3, 2025 · pp. 1–12 Read article