Numerical Modeling Of Sand-Casting Process Parameters That Minimize Shrinkage Defect In Case For Aluminum Alloy (Al-242 Grade)

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.