International Journal of Advance Research in Science, Engineering and Technology, Vol.01, Issue 02, pp.

13-17

THE APPLICATION OF SOLID MODELLING, AND CASTING SIMULATION TECHNOLOGIES FOR BILLET PRODUCTION
1 1

MR. V.R.Maniar, 2 PROF. Bharat Gupta, 3 MR. Abhisek Chaubey

M.TECH. [Machine Design], Student, Department of Mechanical Engineering, Oriental Institute of Technology & Science, Bhopal, Madhaypradesh. . 2 H.O.D., Department of Mechanical Engineering, Oriental Institute of Technology & Science, Bhopal, Madhaypradesh.

.
Assitant Professor, Department Of Mechanical Engineering, Oriental Institute of Tech. & Science, Bhopal, Madhaypradesh.
3

vrmaniar@gmail.com, bharatgupta@oriental.ac.in, abhishekchby2@oriental.ac.in

Abstract: There is prime requirement of billet in the industries. Manufacturing of billets are very critical because of huge requirement of customers and in short time period it should be fulfilled with highest quality and less price due to cut throat competition. Computer simulation tools are used to reduce a time for development of a component. ProCAST computer simulation software is used to visualize a complete solidification process which is not possible during real casting. Defects such as shrinkage, porosity, gas porosity, and unfilled mould, cold shut etc. can be graphically observed. Initially CAD model of hook has been prepared in Solid-Works, then export to GEOMESH for meshing. The mesh model is import to ProCAST for Finite Elemental Analysis. Process parameters such as gate design and pouring time has been applied as a simulation inputs. Simulation provides good understanding about temperature distribution, shrinkage porosity, fraction solid solidification time and residual stresses. Keywords- Casting, ProCAST software and simulation.

mechanical properties and dimensions demands increased emphasis on productivity and manufacturing of accurate and precise components. In this paper, CAD (PROE, CATIA, UNIGRAPHICS etc.) is used to assist the designer in visualizing 2D drawing into virtual-cum-real 3D models from any view; CAM (CIMATRON, DELCAM and IDEAS) to convert 3D part geometry into the unit process of manufacturing resulting into process planning and route sheet; CAE (ANSYS, PROMECHANICA, ABACUS) to assist in testing physical (thermal), mechanical (mass, area) and chemical (composition) properties of components. In this simulation work, the effect on shrinkage porosity by application of different thicknesses of chills at most susceptible region in mould is investigated. The ProCast simulation method was employed in which solidification patterns resulting from different dimensions of extruded portion. [1] [2]

I. Introduction
The actual production of castings is quite complicated because it is associated with many defects such as blowholes, pin holes, cavities, porosity, coring, macro segregation, cracks, deformations which results in rejection of castings with due regard to quality. Therefore, the production of good quality castings is the need of hour and it necessitates the expertise in resources and technology hand-in-hand in order to maintain higher level of productivity. The need to produce castings that are lowest in cost and highest possible in quality with least metallurgical defects and most stable in

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International Journal of Advance Research in Science, Engineering and Technology, Vol.01, Issue 02, pp. 13-17

Fig.1 Improvement in New Design [3]

Figure 3. Mould

Billet Drawing:-

Fig.2 Simulation Flow Diagram [4] [5]

I. PROBLEM FORMULATION Product Details: - Billets (Raw Material for Foundry) Mould Drawing Material: En 8D (Annealed Condition)

Figure 4. Casting

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International Journal of Advance Research in Science, Engineering and Technology, Vol.01, Issue 02, pp. 13-17

II. PROCEDURE FOR ANALYSIS 1. Create 3D model of casting and mould in any 3D modelling Software.Here Mould and Casting are modelled in Solidworks.

Figure 7. Mould and Casting in Procast Figure 5. 3D Model of Mould

3. Apply material to mould and Casting.

Figure 6. Assembly Model of Mould and Casting After Creating Geometry save this geometry as any neutral file here it is saved as .IGES. 2. Import 3D model in Mesh Cast as shown in figure.

Figure 8. Material Defination for Mould and Casting 4. Create mesh Stastics of mesh

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International Journal of Advance Research in Science, Engineering and Technology, Vol.01, Issue 02, pp. 13-17

Number of materials Total Number of Nodes Total Number of Elements Type of Element

:2 : 2686 : 11338 : Tetrahedral

7. Getting Results of Analysis in View Cast.

Figure 9. Meshed Model Figure12. Temperature distributions during mould filling in twelve steps, and quenching to room temperature. 5. Apply Boundry Condition(inlet).

Temperature presented for half model

Figure 10. Application of Boundary Condition.

6. Apply Solver Control Criteria.

Figure13. Temperature distributions during solidification at different times in various temperature- displacement analysis. Objective of the study is to validate casting simulation software(procast) by comparing that result with practical data for same component and after validation how we can reduce cycle time and residual stresses of the casting Process is to be studied with procast.[6] [7] Figure 11. Solver Control Criteria Practical data for ingot cooling are as under. Cycle time for the cooling Process 6 sec

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International Journal of Advance Research in Science, Engineering and Technology, Vol.01, Issue 02, pp. 13-17

Quenching Medium Air Residual Stress generated 20-24 N/mm2

IV.ACKNOWLEDGEMENTS:
I am very thankful to Rupali Industries, Rajkot for help me in this research work.

V. References:
[1] Application of Commercial Software Package Procast to the Prediction of Shrinkage Porosity in Investment Castings, accessed during February, 2011. [2] Nandita Gupta, Manish Kant, Jena Mohan Kerketta Simulation of a Rectangular Object with Shrinkage Defect. Vol. 57, No.5, May 2011 Indian Foundry Journal. [3] B. Ravi, Casting Simulation and Optimization: Benefits, Bottlenecks, and Best Practices, Indian Foundry Journal, 54(1), 47-52, 2008. [4] Rabindra Behera 1, Kayal.S 1, Sutradhar.G 2 Solidification behavior and detection of Hotspots in Aluminum Alloy castings: Computer Aided Analysis and experimental validation Volume 1, No 4, 2011 [5] Maria Jos Marques, CAE Techniques for Casting Parameter Optimization [6] Prof. Ravi B, Metal Casting: Computer-Aided Design and Analysis, PHI, New Delhi, ISBN 81 203 2726 8, 4th print, 2008. [7] Internal Databases of ProCAST Software.

Figure 14. Cooling Process at Different time step

Figure 14 Cooling Process at Different timestep Here whole casting process is divided in tweleve substep.cooling for each step has been shown in above figure.14. Comparising each substep with practical graph we can say that Above Results are Quite maching with the Practical data so we can say that casting simulation software are quite reliable to eliminate trail and error method. III. CONCLUSION The application of computer aided methoding, ,solid modelling, and casting simulation technologies in foundries can able to minimize the bottlenecks and no value added time in casting development, as it reduces the number of trial casting required on the shop floor. The application of casting simulation software based on finite element method and vector element method shows good results and matched with the experimental results. The benchmark study reveals that the use of casting simulation software reduces the iteration time for modification of methoding. It has also proven to be very useful for verifying the manufacturability of a casting and improving it by minor modifications to part geometry, before freezing the design in early stages of product lifecycle.

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