Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation

Nazma Sultana; Md. Rafiquzzaman; Younosur Rahman; Apurba Das

doi:doi:10.11648/j.ijmea.20180606.12

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Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das

Published in International Journal of Mechanical Engineering and Applications (Volume 6, Issue 6)

Received: 13 September 2018 Accepted: 2 November 2018 Published: 28 January 2019

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Abstract

Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.

Published in	International Journal of Mechanical Engineering and Applications (Volume 6, Issue 6)
DOI	10.11648/j.ijmea.20180606.12
Page(s)	150-160
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Shrinkage Porosity, Improper Solidification, Air Entrapment, Mould Erosion, Click2cast

References

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APA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. (2019). Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. International Journal of Mechanical Engineering and Applications, 6(6), 150-160. https://doi.org/10.11648/j.ijmea.20180606.12

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ACS Style

Nazma Sultana; Md. Rafiquzzaman; Younosur Rahman; Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int. J. Mech. Eng. Appl. 2019, 6(6), 150-160. doi: 10.11648/j.ijmea.20180606.12

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AMA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int J Mech Eng Appl. 2019;6(6):150-160. doi: 10.11648/j.ijmea.20180606.12

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@article{10.11648/j.ijmea.20180606.12,
  author = {Nazma Sultana and Md. Rafiquzzaman and Younosur Rahman and Apurba Das},
  title = {Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {6},
  number = {6},
  pages = {150-160},
  doi = {10.11648/j.ijmea.20180606.12},
  url = {https://doi.org/10.11648/j.ijmea.20180606.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20180606.12},
  abstract = {Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.},
 year = {2019}
}

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TY  - JOUR
T1  - Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation
AU  - Nazma Sultana
AU  - Md. Rafiquzzaman
AU  - Younosur Rahman
AU  - Apurba Das
Y1  - 2019/01/28
PY  - 2019
N1  - https://doi.org/10.11648/j.ijmea.20180606.12
DO  - 10.11648/j.ijmea.20180606.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 150
EP  - 160
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20180606.12
AB  - Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.
VL  - 6
IS  - 6
ER  -

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Author Information

Nazma Sultana

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh
Md. Rafiquzzaman

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh
Younosur Rahman

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh
Apurba Das

Department of Industrial Engineering and Management, Khulna University of Engineering & Technology (KUET), Khulna, Bangladesh

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APA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. (2019). Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. International Journal of Mechanical Engineering and Applications, 6(6), 150-160. https://doi.org/10.11648/j.ijmea.20180606.12

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ACS Style

Nazma Sultana; Md. Rafiquzzaman; Younosur Rahman; Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int. J. Mech. Eng. Appl. 2019, 6(6), 150-160. doi: 10.11648/j.ijmea.20180606.12

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AMA Style

Nazma Sultana, Md. Rafiquzzaman, Younosur Rahman, Apurba Das. Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation. Int J Mech Eng Appl. 2019;6(6):150-160. doi: 10.11648/j.ijmea.20180606.12

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@article{10.11648/j.ijmea.20180606.12,
  author = {Nazma Sultana and Md. Rafiquzzaman and Younosur Rahman and Apurba Das},
  title = {Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {6},
  number = {6},
  pages = {150-160},
  doi = {10.11648/j.ijmea.20180606.12},
  url = {https://doi.org/10.11648/j.ijmea.20180606.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20180606.12},
  abstract = {Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.},
 year = {2019}
}

Copy | Download

TY  - JOUR
T1  - Solidification and Filling Related Defects Analysis Using Casting Simulation Technique with Experimental Validation
AU  - Nazma Sultana
AU  - Md. Rafiquzzaman
AU  - Younosur Rahman
AU  - Apurba Das
Y1  - 2019/01/28
PY  - 2019
N1  - https://doi.org/10.11648/j.ijmea.20180606.12
DO  - 10.11648/j.ijmea.20180606.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 150
EP  - 160
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20180606.12
AB  - Solidification as well as filling has great influences on the quality of cast products. In modern competitive world for increasing the quality of products these two steps draw higher attention to casting engineers. This case study is just one of the followings of the above mentioned objective. The aim of the present work is to reduce the rejection rate of cast products in a foundry shop due to casting defects in sand casting process using a computer aided simulation technique. In general conventional techniques require a larger number of trials with higher costs for checking outputs when the number of process parameters increase that can be reduced using simulation. For the simplification in this analysis grain size of sand, material quality, casting process parameters are considered uniform for all cases. Only the positional and dimensional variances are taken in considerations for defects analysis. It is found that defects such as shrinkage porosity, improper solidification, air entrapment, mould erosion are directly related with gating and feeding system design and although other process parameters are considered uniform but this defects will be changed with changing the design parameters. In this case Click2cast casting simulation software is used for mould filling and solidification analysis and it is observed that proposed gating and feeding system design improves casting yield approximately 15% more than conventional gating and feeding system. The validation of simulation is proved through experimental trials in foundry shop.
VL  - 6
IS  - 6
ER  -

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