Casting Design Modification to Improve Casting Yield in Producing Thin Wall Ductile Iron Plate

2018 ◽  
Vol 929 ◽  
pp. 10-17
Author(s):  
Rianti Dewi Sulamet-Ariobimo ◽  
Yun Gemilang ◽  
Donanta Dhaneswara ◽  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno
Keyword(s):  
Cooling Rate ◽  
Ductile Iron ◽  
Simulation Analysis ◽  
Casting Process ◽  
Ferrite Matrix ◽  
Thin Wall ◽  
Casting Simulation ◽  
Design Modification ◽  
Casting Yield ◽  
Casting Design

Cooling rate plays an important role in the formation of thin wall ductile iron microstructure due to their thickness, which is 3 mm below based on Stefanescu. Cooling rate is closely related to casting design and determines the microstructure. This paper discusses the effect of casting design modification to casting yield and microstructures. Modification was made on a patented design used previously to produce thin wall ductile iron plates. The design was minimized and casting simulation was used to analyze castability of the design. After that, the design were casted in several pouring temperatures. Improvement was made to casting design based on the failure during the experiment. Casting process took place after simulation analysis. The casting product was fully casted as shown by the simulation. The casting yield has improved to 28%. When all plates were examined for microstructure, the result showed that all the microstructure of the plates was not graphite in ferrite matrix as occurred in the patented design but it was graphite in pearlite matrix.

Cooling Rate Analysis of Thin Wall Ductile Iron Using Microstructure Examination and Computer Simulation

2015 ◽  
Vol 752-753 ◽  
pp. 845-850 ◽  
Author(s):  
Rianti Dewi Sulamet-Ariobimo ◽  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno
Keyword(s):  
Computer Simulation ◽  
Cooling Rate ◽  
Ductile Iron ◽  
The Other ◽  
Thin Wall ◽  
Casting Simulation ◽  
Rate Analysis ◽  
Microstructure Examination ◽  
Solidification Mechanism ◽  
Casting Design

Cooling rate plays an important role in thin wall ductile iron solidification, due to their thickness. Casting simulation is use as a tool to estimate the cooling rate. In the other hand, every microstructure has its own cooling rate. This paper explores the similarity of solidification mechanism between simulation and graphite characteristics. Three types of casting design simulated and produced. Solidification mechanism is analyzed based on cooling rate sequence and trend line matching. Temperature gradient and thermocouple function represent simulation while graphite characteristic represent experiment. The result shows that similarity in solidification mechanism is not found between simulation with experiment due to lack of parameters in both sides.

The Effect of Vertical Step Block Casting to Microstructure and Mechanical Properties in Producing Thin Wall Ductile Iron

2013 ◽  
Vol 789 ◽  
pp. 387-393 ◽  
Author(s):  
Rianti Dewi Sulamet-Ariobimo ◽  
Johny Wahyuadi Soedarsono ◽  
Is Prima Nanda
Keyword(s):  
Mechanical Properties ◽  
Ductile Iron ◽  
Plate Thickness ◽  
Thin Wall ◽  
Microstructure And Mechanical Properties ◽  
Casting Yield ◽  
Automotive Parts ◽  
Vertical Step ◽  
Casting Design ◽  
Filling And Solidification

Thin wall ductile iron (TWDI) is introduced to fulfill the needs of lighter material in automotive parts that will reduce fuel consumption. Problem occurs during the production of TWDI due to the casting thickness. TWDI casting thickness classified to below 5 mm. Many designs have been made to answer the problem in producing thin wall ductile iron. Soedarsono et al established vertical step block casting design. This design based on Y-block principle that allows direct pouring of liquid metal to the mold without passing any gating system. This design will increase casting yield. The parameter of this research is pouring basin placement to study the effect of plate arrangement to filling and solidification. This research is conducted to see the effect of pouring basin placement to microstructure and mechanical properties of TWDI. The Design is made to produce 5 plates with different thickness that is 1, 2, 3, 4, and 5 mm. All of the plates arranged parallel in line. Pouring basin located in 2 ways. The first type located pouring basin above the plate of 5 mm thickness while the second one located it above the plate with 1 mm thickness. The first type coded as T4 while the second coded as T5. The moulds made from furan sand. The result shows although cold shut occurred in both pouring basin placements due to pouring discontinuity but shrinkage only formed in T5 on its plate with 1 mm thickness. Microstructure of all the plates presented nodule graphite in pearlite matrix. Carbide and skin effects also detected. Average nodularity is above 80% while the nodule count is between 614 to 1269 nodule/mm2. Most of the Brinell hardness number exceeded maximum limit given by JIS G5502 but the UTS is below the minimum limit except for 3 mm plate thickness of T5. All elongation values below the minimum standard. The results confirm that pouring basin location is important in casting design following Y-Block principle.

Effect of Casting Design to Microstructure and Mechanical Properties of 4 Mm Twdi Plate

2013 ◽  
Vol 702 ◽  
pp. 269-274 ◽  
Author(s):  
Rianti Dewi Sulamet-Ariobimo ◽  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno
Keyword(s):  
Mechanical Properties ◽  
Cooling Rate ◽  
Skin Effect ◽  
Flow Simulation ◽  
Ferrite Matrix ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Microstructure And Mechanical Properties ◽  
Casting Design

Casting design is chosen by Soedarsono et al to maintain cooling rate in producing thin wall ductile iron (TWDI). Cooling rate should be maintained to prevent carbide formation. This paper discusses the effect of gating system design on microstructure and mechanical properties of 4 mm TWDI plate. A casting design based on vertical gating system is made to produce TWDI plates with the thickness of 1, 2, 3, 4, and 5 mm. This vertical system allows plates to function as runner which will helps in preventing premature solidification. Three designs were made. These designs are coded as T1, T2, and T3. These three designs were also used in making 1, 2, 3, and 5 mm TWDI plates of which the result has been published. Z-Cast is used to conduct a casting design simulation for filling flow and solidification. The result of flow simulation shows that the filling flow is resulted in two kinds. The result of solidification specifies that the 4 mm TWDI plates solidify in the third place. The result of the experiment highlights that in all of the designs, which have microstructure and consisted of nodule graphite in ferrite matrix, no trace of carbide and skin effect are formed. The length of skin effect varies in all of the designs. The highest nodularity is only 80% while nodule count is 931 nodules/mm2. Brinell hardness number for all of the design is beyond the standard given by JIG G5502. As for UTS, yield strength and elongation none of the designs exceeds the minimal standard. The result of the experiment does not confirm the result of the simulation. In sum, compared to the previous result, the curve trends of 4 mm TWDI plates look similar to 2 mm TWDI plates.

Effect of Casting Design to Microstructure and Mechanical Properties of 2 Mm Twdi Plate

2013 ◽  
Vol 652-654 ◽  
pp. 2404-2408 ◽  
Author(s):  
Rianti Dewi Sulamet-Ariobimo ◽  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno
Keyword(s):  
Mechanical Properties ◽  
Cooling Rate ◽  
Skin Effect ◽  
Flow Simulation ◽  
Ferrite Matrix ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Microstructure And Mechanical Properties ◽  
Casting Design

It is important to strictly maintain the cooling rate in producing thin wall ductile iron (TWDI) to prevent carbide formation. There are many ways to control cooling rate whereas casting design is the most independent one. This paper discusses the effect of gating system design on microstructure and mechanical properties of 2 mm TWDI plate. A casting design based on vertical gating system is made to produce TWDI plates with the thickness of 1, 2, 3, 4, and 5 mm. This vertical system allows plates to function as runner. This situation helps in preventing premature solidification. There are three designs in which they are coded as T1, T2, and T3. These three designs were also used in making 1, 3, and 5 mm TWDI plates of which the result has been published. Z-Cast is used to conduct a casting design simulation for filling flow and solidification. The result of flow simulation shows that the filling flow is resulted in two kinds. The result of solidification specifies that in T1 and T2 the 2 mm TWDI plates solidify in the same time as 1 mm TWDI plate. Furan sand was used as moulds in the experiment. The result of the experiment highlights that in all of the designs, which have microstructure and consisted of nodule graphite in ferrite matrix, no trace of carbide and skin effect are formed. The length of skin effect varies in all of the designs. The highest nodularity is only 86% while nodule count is 1344 nodules/mm2. Brinell hardness number for all of the design is beyond the standard given by JIG G5502. As for UTS and elongation none of the designs exceeds the minimal standard. The result of the experiment does not confirm the result of the simulation. In sum, compared to the previous result, the curve trends of 2 mm TWDI plate combine the curve trends of 1 and 3 mm TWDI plates.

Effect of Casting Design to Microstructure and Mechanical Properties of 5 mm TWDI Plate

2012 ◽  
Vol 152-154 ◽  
pp. 1607-1611 ◽  
Author(s):  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno ◽  
Rianti Dewi Sulamet-Ariobimo
Keyword(s):  
Mechanical Properties ◽  
Cooling Rate ◽  
Skin Effect ◽  
Raw Material ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Nodule Count ◽  
Microstructure And Mechanical Properties ◽  
Casting Design

In producing thin wall ductile iron (TWDI) cooling rate must be strictly maintained to prevent carbide formation. There are many ways to control cooling rate BUT the most independent one is by casting design. By choosing this parameter major changes in equipment and raw material used in the foundry can be avoided. This paper discusses the effect of gating system design on microstructure and mechanical properties of 5 mm TWDI plate. A casting design based on vertical gating system is made to produce 1, 2, 3, 4, and 5 mm TWDI plates. Plate with 5 mm thickness becomes an interesting subject due to its position as the thickest and furthest from ingate in casting design with a new concept. There are three designs coded as T1, T2, and T3. These three designs were also used in making 1 and 3 mm TWDI plates of which the result has been published. The plate with 5 mm thickness will be used for automotive components. Casting design simulation for filling flow and solidification were conducted with Z-Cast. Result of flow simulation shows that the filling flow happens in two kinds. Result of solidification shows that T3 has the highest solidification rate. In the experiment, the moulds used were furan sand. Experiment result shows that all the designs have microstructure consisting of nodule graphite in ferrite matrix, no trace of carbide and skin effect are formed. Skin effect length is various for all designs. The highest nodularity is only 72% and nodule count shows only 700 nodules/mm2. Brinell hardness number for all design is beyond standard given by JIG G5502. As for UTS and elongation none of the designs exceed the minimal standard. Experiment results confirms simulation result. Compared to the previous result nodularity and nodule count decrease and curve trends for every result are not similar.

Effect of Casting Design to Microstructure and Mechanical Properties of 1 mm TWDI Plate

2011 ◽  
Vol 110-116 ◽  
pp. 3301-3307 ◽  
Author(s):  
Johny Wahyuadi Soedarsono ◽  
Rianti Dewi Sulamet-Ariobimo
Keyword(s):  
Mechanical Properties ◽  
System Design ◽  
Cooling Rate ◽  
Skin Effect ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Microstructure And Mechanical Properties ◽  
Minimal Standard ◽  
Casting Design

In producing thin wall ductile iron (TWDI) cooling rate must be strictly maintaned to prevent carbide formation. There are many ways to control cooling rate and one of these is through casting design, especially gating system design. This paper discusses the possibility to produce 1 mm TWDI plate and also to note the effect of gating system design to microstructure and mechanical properties. Casting design based on gating system design are made to produce 1 mm TWDI plate. The 1 mm TWDI plates will be used for fin. There are three design and coded as T1, T2, and T3. The moulds used were made from furan sand. Beside the experiment, casting design simulation with Z-Cast was also conducted to ensure the completion of producing 1 mm TWDI plate. Simulation result showed that all designs could produce 1 mm TWDI plate. Result from experiment showed that all the designs have microstructure consisting of nodule graphite in ferrite matrix and carbide. Apart from mentioned microstructure there is also skin effect. The difference between all designs lies in carbide content and skin effect width. All the nodularity exceeded 80% and nodule count exceeded 1000 nodule/mm2. Brinell hardness number for all design exceeded minimal standard given by JIG G5502. As for UTS only T2 design can exceed the minimal standard. There is a contradictive result between experiment and simulation in cooling rate.

Simulation Analysis of HPDC Process with Automobile Part by CAE

2014 ◽  
Vol 804 ◽  
pp. 315-318
Author(s):  
Hong Kyu Kwon ◽  
Boong Joo Lee
Keyword(s):  
Simulation Analysis ◽  
Casting Process ◽  
Simulation Software ◽  
New Production ◽  
Automobile Part ◽  
Casting System ◽  
Gate System ◽  
Development Paradigm ◽  
Casting Design ◽  
Cae Simulation

In present casting industries, product development paradigm is shifting from traditional trial-and-error to proof-of-concept based on CAE-enabled simulation. In the new production development paradigm, CAE simulation plays an important role because it models the entire casting process and reveals the dynamic behavior of the casting system in working conditions. In this research, Computer Aided Engineering (CAE) simulation was performed by using the simulation software (AnyCasting) in order to optimize casting design of an automobile part (Upper Oil Pan) which is well known and complicated to achieve a good casting layout. The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process, internal porosities caused by air entrapments were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were also predicted.

Integrated Database Development for Casting Design and its Application to Casting Simulation

2014 ◽  
Vol 783-786 ◽  
pp. 2142-2147
Author(s):  
In Sung Cho ◽  
Jeong Tae Kim ◽  
Jeong Kil Choi
Keyword(s):  
Thermophysical Properties ◽  
Casting Process ◽  
Calphad Approach ◽  
Technical Knowledge ◽  
Casting Simulation ◽  
Database Development ◽  
Casting Alloys ◽  
Modeling Data ◽  
Casting Design ◽  
Shape Data

Development of integrated database including casting shapes with their casting design, technical knowledge, and thermophysical properties of the casting alloys were introduced in the present study. For the shape database, a number of casting products are scanned by using by using industrial computer tomography and compiled to the shape database. Each shape data in the database has also parametric 3D modeling data, not only the product but also its casting design. If casting engineer want to design new casting, similar casting shape with casting design can be easily retrieved from the shape database, and easily modified and adapted to the new casting. Technical knowledge of the various casting processes and their manufacturing process of the castings were compiled and the search engine for the knowledge was developed. Database of thermophysical properties of the casting alloys were obtained by the experimental study or calculation based on CALPHAD approach, and the properties were used for the in-house computer simulation of casting process. The databases were linked with intelligent casting expert system developed in e-design center, KITECH. It is expected that the databases can help non casting experts to devise the casting and its process. Various examples of the application by using the databases were shown in the present study.

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