Study on Solidification Behavior of Aluminium alloy ( LM 6 ) Castings by using Computer aided Simulation software
Method layout of a casting is an important aspect of tooling development. It involves decisions regarding part orientation in mould, parting line, cores, cavity layout, feeders, neck and gating system. An improper method layout leads either poor quality or low yield, which affects the productivity. Method design is mostly carried out manually, using 2D drawing of the cast part. Then tooling is fabricated the sample castings are produced to 3-4 trials which involves lot of production cost in the from of wastage of manpower, time and hamper the day to day schedule of the particular production. Computer simulation provides a clear insight regarding the location and extent of internal defects, ensuring casting are right as first time and every time. In the present study plate castings were considered to study the solidification behavior of Aluminium Alloy (LM6) at different sizes of riser and riser neck. The VEM based casting simulation software is used to study the solidification behavior of above castings. The simulated results were compared with the experimental results. It is expected that this work will be of immense importance equally to the academicians as well as to the industrial methoding engineers.
Hot spots in castings: computer-aided location and experimental validation
The thermal vector technique driven by section geometry and independent of thermophys. properties of the metal or mold is a sensitive, versatile, and efficient method for hot spot identification in complex sections by using a personal computer. Location of the hot spot, as affected by re-entrant and external corners, filleting, fins, cores, and curved contours, is consistent with heat transfer principles. The results are in close agreement with those obtained from the finite- element method and actual experimentation on Al-12%Si alloy in Na silicate-bonded CO2-hardened sand molds.
Part, Tooling and Method Optimisation Driven by Castability Analysis and Cost Model
A high percentage of casting defects in jobbing foundries can be attributed to low compatibility between part requirements, tool/method design and process capabilities. These three must be optimized in integrated manner to achieve the desired quality at the least cost without shop-floor trials. For this purpose, we present a scientific approach comprising method design, process simulation, quality evaluation and cost estimation. Simulation results are evaluated using three quality indices: mouldability, fillability and feedability. Costing elements include tooling, material and process. An industrial case study is presented to illustrate the entire approach. Its greatest benefits are obtained during part design, when it is easy to make changes to ensure high compatibility between various parameters.