Numerical Simulation of Sand Casting Process: A Case Study on Globe Valve

There are many kinds of casting defects such as insufficient pouring, cooling separation, crack, and shrinkage and soon on were formed in the mold filling and the solidification process, which affect the final casting performance. Based on the mathematical models of mold filling and solidification process, the numerical simulation of chilled cast iron camshaft in sand casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkages were predicted. According to the simulation results, an improved technology is proposed, and the shrinkages were eliminated efficiently. The simulation results are in good agreement with practical.

Download Full-text

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

International Journal of Business and Systems Research ◽

10.1504/ijbsr.2019.098666 ◽

2019 ◽

Vol 13 (2) ◽

pp. 226

Author(s):

Mahantesh M. Ganganallimath ◽

Suraj Dhondiram Patil ◽

E.V. Gijo ◽

Roopa B. Math ◽

Vijaykumar Hiremath

Keyword(s):

Six Sigma ◽

Casting Process ◽

Sand Casting ◽

Green Sand

Download Full-text

CAD/CAM DESIGN AND GENETIC OPTIMIZATION OF FEEDERS FOR SAND CASTING PROCESS

Facta Universitatis Series Mechanical Engineering ◽

10.22190/fume1602147d ◽

2016 ◽

Vol 14 (2) ◽

pp. 147 ◽

Cited By ~ 5

Author(s):

Nedeljko Dučić ◽

Žarko Ćojbašić ◽

Radomir Radiša ◽

Radomir Slavković ◽

Ivan Milićević

Keyword(s):

Numerical Simulation ◽

Computer Aided Design ◽

Casting Process ◽

Sand Casting ◽

Genetic Optimization ◽

Design And Optimization ◽

Computer Aided ◽

Cad Cam ◽

Feeder Design ◽

Aided Design

The paper proposes methodology of feeder design and optimization for sand casting process. Casting part is a part of excavator buckets, i.e. holder of the cutting tooth. Process of design and optimization is based on the application of the rules, which are the result of many years of work researchers in the field of metal casting. Computer Aided Design (CAD) is used as a methodology in the design of feeders. Genetic Algorithm (GA) as an artificial intelligence technique is used in the optimization process of the feeder geometry. Computer Aided Manufacturing (CAM) is used as methodology that involves numerical simulation of the casting process. Numerical simulation is used to verify the validity of the optimized geometry of the feeding system.

Download Full-text

Taguchi-Based Six Sigma Defect Reduction of Green Sand Casting Process: An Industrial Case Study

Journal of Enterprise Transformation ◽

10.1080/19488289.2013.860415 ◽

2014 ◽

Vol 4 (2) ◽

pp. 172-188 ◽

Cited By ~ 1

Author(s):

Joseph C. Chen ◽

Abhilash Reddy Buddaram Brahma

Keyword(s):

Six Sigma ◽

Casting Process ◽

Sand Casting ◽

Green Sand ◽

Industrial Case Study ◽

Defect Reduction

Download Full-text

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

International Journal of Business and Systems Research ◽

10.1504/ijbsr.2019.10018717 ◽

2019 ◽

Vol 13 (2) ◽

pp. 226

Author(s):

Vijaykumar Hiremath ◽

Roopa B. Math ◽

Mahantesh M. Ganganallimath ◽

Suraj Dhondiram Patil ◽

E.V. Gijo

Keyword(s):

Six Sigma ◽

Casting Process ◽

Sand Casting ◽

Green Sand

Download Full-text

Numerical Modeling on Sand Casting Process of a Wind Turbine Part

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.121-126.1367 ◽

2011 ◽

Vol 121-126 ◽

pp. 1367-1371 ◽

Cited By ~ 2

Author(s):

Qing Ming Chang ◽

Yin Kai Yang ◽

Xia Chen ◽

Chang Jun Chen ◽

Si Qian Bao

Keyword(s):

Numerical Simulation ◽

Numerical Modeling ◽

Wind Turbine ◽

Research Work ◽

Casting Process ◽

Mold Filling ◽

Sand Casting ◽

Shrinkage Cavity ◽

Pouring Temperature ◽

Filling And Solidification

In this research work, ProCAST software is employed to study the sand casting process of a box-type part for wind turbine. The casting part is big in size, non-uniform in wall thickness, and heavy in some local positions. Shrinkage cavity and porosity are very likely to from at these locations. By numerical simulation, the influence of the parameters such as pouring temperature, chills, riser on mold filling and solidification is analyzed. Simulation researches reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced.

Download Full-text

OPTIMISATION OF SAND CASTING PROCESS FOR IMPELLER USING TAGUCHI METHODOLOGY

NED University Journal of Research ◽

10.35453/nedjr-ascn-2019-0041 ◽

2020 ◽

Vol XVII (2) ◽

pp. 23-33

Author(s):

Faisal Hafeez ◽

Salman Hussain ◽

Wasim Ahmad ◽

Mirza Jahanzaib

Keyword(s):

Surface Roughness ◽

Surface Defects ◽

A356 Alloy ◽

Casting Process ◽

Sand Casting ◽

Gate Length ◽

Taguchi Methodology ◽

Confirmatory Tests ◽

Binder Ratio ◽

Response Measures

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

Download Full-text