Abstract:
In today’s world a casting production without any defect is almost impossible as well as the
foundry manufacturing in developing countries have a major problem of quality and productivity
because of involvement of the number of process parameters in casting process which are difficult
to control. In this study, the casting product is faced shrinkage defects which is causing one of
chronic problems. Though the process is completely uncontrolled, defects in casting are observed
and hence casting process is identified as process of uncertainty which challenges explanation
about the cause of casting defects. The main objective of this study is to analyze the effects of
casting process parameters and reduce the shrinkage defect in Aluminium alloy product. To
overcome the process of analysis 3-D model is done by Solid work, by ProCAST the temperature
distribution and shrinkage porosity defect indication are performed, ANSYS for casting simulation
is helpful to visualize solidification, cooling and to predict the location of external defects on
product such as shrinkage porosity defect and hot spot, by Taguchi method the three important
input parameters such as pouring temperature, pouring riser size and pouring time are selected and
compared which causes shrinkage defect on cast product separated. The real-time application of
the study reflects from the fact that experimentation is performed on nine different casting practical
data obtained from experimentation is used for simulation. Shrinkage defects has also been
quantified through experimental validation studies and compared well with casting process
simulation. The simulation of ANSYS result is validated with experimental result. The results
indicate that the selected process parameters significantly cause shrinkage defects in the workshop.
It is observed from experimental trials in a workshop that the average value of minimum casting
defect is 3.01% for aluminium production. Improvement excreted new gating and feeding system
design to reducing shrinkage defect to improve in casting yield 88.9% observed.
