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

Bhushan S. Kamble, Sandeep M. Kadane, Sandesh B. Sangale

Abstract


The metal casting is a complicated but a mass production manufacturing technique. But on the other
hand, the chances of casting rejection are also more if proper attention is not made at every stage of
casting production. In the metal casting process, higher yield and minimum defects level are expected
by the foundry industries. In the present global and competitive world metal casting industries needs
to perform efficiently with a reduction in rejections. This requirement can be fulfilled by a proper
method 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. The
regions 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 an
important role in maximizing casting yield. The objective of this study is to study effect of feeder size
and location on casting defect formation like hotspot, microporosity and shrinkage in Aluminum
casting 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 by
green sand-casting process and with Click2Cast casting simulation software.


Keywords


Metal casting, hotspot, virtual casting simulation, riser, casting yield

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