STM Journals Peer-reviewed research from Consortium e-Learning Network

Trends in Machine design

Autonomous Optimization, Method Design of Casting and Its Experimental Validation: A Case Study

  1. Bhushan S. Kamble
  2. Sandeep M. Kadane
  3. Sandesh B. Sangale

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 requirement can be fulfilled by a propermethod design by casting simulation. The aim of the present study is to identify regions of hot spots,micro porosity, and shrinkage formation in a ‘T’ shape junction Aluminum base alloy casting. Theregions with heavy cross section are prone to getting produced with hot spot and shrinkage defect.Here various experiments were conducted with varying Feeder and neck dimensions which plays animportant role in maximizing casting yield. The objective of this study is to study effect of feeder sizeand location on casting defect formation like hotspot, microporosity and shrinkage in Aluminumcasting T Section and to identify most influencing gating system design factor like feeder dimension.The T shaped model is used as bench mark in prediction of defect location of Al-Cu cast alloy bygreen sand-casting process and with Click2Cast casting simulation software.

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