Optimization of sealing casting by identifying solidification defect and improvement of strength by casting simulation

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 1247
Optimization of sealing casting by identifying solidification defect and
improvement of strength by casting simulation
Suhas M. More1, R. M. Chanmanwar2
1Student, Mechanical Engineering Department, Walchand College of Engineering, Sangli, Maharashtra,
India
2Asst. Prof. Mechanical Engineering Department, Walchand College of Engineering, Sangli, Maharashtra,
India
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Abstract - The casting industry employsavarietyof ways to
address casting fault issues. A large number of casting
rejections results in a waste of both money and effort. Single
flaws in casting might have a single or several causes, thus it's
critical to figure out what's causing the problem. This
industry's productivity has risen to an all-time high. Modern
technology has reduced resource use while simultaneously
reducing faults. Adopting a more controlled approach to
describing, recognizing, and regulating the underlying cause
of an issue will be advantageous. The primary goal of this
research is to identify solidification defect and minimize it by
optimizing new design with help of casting simulation
software. This research will aid in improving strength of
material and hence quality.
Key Words: Sand casting, Solidification defect, ProCAST,
L-type Sealing casting, shrinkage porosity, Misrun
1. INTRODUCTION
Casting is one of the main economical production processes
used in industry and is a complex process that involves
important metallurgical and mechanical aspects. The rate of
solidification largely determines the microstructure, which
in turn determines mechanical properties such as strength,
hardness, machinability, etc. The location, size, and shape of
risers in a casting depend on the shape, mold design, and
heat of the casting, properties of the metal and other factors,
process parameters. Improperly designed riser and gate
systems will always result in defective moldswithshrinkage
cavities or poor experimental results, which are always
better for mold design and development and to achieve
optimal process parameters.
However, this can be expensive, time consuming, and in
some cases impossible. Therefore, the casting simulation
process is a convenient way to properly design a riser
system and analyze the effect of various parameters. The
number of foundry simulation programs in India is also
increasing day by day, as it essentially replacesorminimizes
shop floor testing to achieve the desired internal quality in
the maximum possible time. It can greatly reduce iterations
on the shop floor and is mainly used for proof-of-concept.
Simulation programs generally increase the confidence of
foundries when creating more complex castings (complex,
large) with higher margins. It also provides a scientific and
documented basis for quality assurance and certification.
1.1 Related Work
Ravi (2008) have studiedatthebenefitsofcastingsimulation,
bottlenecks and best practices for overcoming bottlenecks
without burial testing, they provide quality assurance and
significantly minimize lead times to cast the first good
sample.
Naveen (2014) has discussed the steps which is included in
simulation the possible source of error and care to be has to
be taken during the time of casting simulation process.
According to him the designer should have confidence in
casting simulation tool which are going to be used. The
confidence level will come only by experience and usage of
the tool to mimic effect of various process parameters.
Prabhakara et al. (2006) have studied on the solidification
mold filling simulation of green sand casting, ductile iron
casting sand, and using casting simulation software such as
PRO CAST, it was concluded that defects such as shrinkage,
porosity, etc. could be eliminated. Itcan also improveyieldof
the casting, optimize the gating system design & mold filling.
Karl B. Rundman explained metal casting procedure, sand
casting procedureand other casting procedure. He discusses
the defects in casting. He also studies the solidification
phenomena in casting procedure.
C. W. Ammen [1979] He discussed the different elements
required in sand castings. He also discussed the defects in
sand casting.
1.2 Problem Definition:
In order to remain competitive in today’s market, a modern
foundry has to take full advantage of the benefits offered by
casting simulation. These allow the foundry man toanalyses
problems in detail, faster, and at an early stage in the design
cycle, thus enabling decisionstobemadetowardsimproving
design and quality. Therefore, the costs and the risk
associated with the trial and error procedure of

experimental castings are minimized. In the present
dissertation we use the casting simulation software to
identify the solidifying defects present in the sealing casting
and an attempt was made to optimize the sealing casting.
1.3 Objectives
The main objective of present investigation is optimization
of sealing casting by casting simulation process.
1. To study the casting procedure, application,problemsand
defects in sealing casting.
2. To do solidification Analysis of the existingsealingcasting.
3. To give solution for the defects like shrinkage, Misrun and
improve strength of sealing casting by using casting
simulation process.
4. To carry out the results of analysis.
2. Methodology
In this chapter, the approach employed in the present work
is briefly discussed. In this research, a sealing casting model
constructed of grey cast iron is examined. For sand casting,
different circumstances are simulated numericallyusingthe
commercial software pro-CAST. Various solidification
performance metrics, including temperature, hotspot, total
shrinkage porosity, voidscontour,andsolidificationcontour,
etc. The existing technology utilized for simulation of
solidification is investigated as the foundation of this work.
At the conclusion of the chapter, the findings obtained using
the existing gating system for the moulds are discussed.
Typically, simulation software consists of three primary
components: (1) Pre-processing (the programme reads the
CAD geometry and generates the mesh),(2)Mainprocessing
(addition of boundary conditions and material data, filling,
and temperature calculations), and (3) Post processing
(presentation and evaluation). Based on Finite Element
technology, ProCAST offers a comprehensive simulation
solution for a wide variety of applications. proCAST's
objective is to construct a finiteelementmodel,configurethe
calculation, execute the analysis, and evaluate the findings.
The following actions (procedures) were carried out in
ProCAST's simulation of the seal casting process.
 Computer-aided design (3D) of a seal casting
featuring a gating systemutilizingtheANSYSDesign
Modeler programme.
 Save the CAD file in IGES format and import it into
the proCAST software using the geometry
transformation tool.
 Mesh the mould and cast using a 2D and 3D surface
mesh and volume mesh.
 Input data includingvolume manager,interfaceHTC
manager, process condition manager, and
simulation parameters, and initiate simulation by
selecting ProCAST with a solver count of four.
Analyze the results with the view cast, such as temperature,
solidification time, and fraction of solid and total shrinkage
porosity. The steps related to simulationareshowninFigure
1.
Fig -1: Steps Involved In Numerical Simulation of
Solidification Process
2.1 Pre-processing (the programme reads the CAD
geometry and generates the mesh)
Figure 2 shows the isometric wireframe view of the casting
mold used for the study. The dimensions of the same are
given as below,
Length = 300 mm, Width = 300 mm, Height = 120 mm.
The model is drawn and developed in the Ansys Design
Modelers software. The developed model is then imported
for the meshing purpose. The meshing of the model is
carried out in two steps, first the surface meshing is carried
out followed by the volume meshing of the model. Both the

surface meshing and volume meshing of the model are
shown in Figure 3 and Figure 4 respectively.
Fig -2: Isometric Wire Frame Model of the Casting Mold
Used For the Study
Fig -3: Surface Meshing Of the Model
Fig -4: Volume Meshing Of the Model
2.2 Main processing (addition of boundary
conditions and material data, filling, and
temperature calculations)
After meshing the main processing stagecomesin picture.In
main processing material assignment, boundary condition
and heat transfer conditions from body to mold should be
given. Material assignment is done in volume manager as
shown in figure 5.
Fig -5: Volume Manager
Boundary conditions aregiveninprocessconditionmanager
as shown in figure 6, in which we generated inlet boundary
condition as BC_inlet_2. In BC_inlet_2 we added mass flow
rate and pouring temperature and also velocity component.
Heat transfer condition from body to mold is given in
interface HTC manager as shown in figure 7.

Fig -6: Process Condition Manager
Fig -7: Interface HTC Manager
2.3 Post processing (presentation and evaluation).
Post processing is the last and important step in the
simulation process. In post processing we got various
contours, graphs charts, etc. our focus in this research is
mainly on the shrinkage porosity, hotspot and misrun
sensitivity. Figure 8 shows total shrinkage porosity of the
existing model which is about 6.67% at different locations.
Fig -8: Total Shrinkage Porosity of Existing Model
Figure 9 shows the contour of hotspot on the existingmodel,
from the figure we may say that existing model has several
hotspots on its top surface. Misrun sensitivity of existing
model is shown in figure 10, from the figure we may
conclude that existingmodel hashighrisk misrunsensitivity.
Fig -9: Hotspot on Existing Model
Fig -10: Misrun Sensitivity of Existing Model
3. Modified Design of L type sealing Casting
In the previous chapter the existing model of L type sealing
casting is simulated inProCASTsoftware. The existingmodel
has several casting defects which needed to be rectified. In
present chapter, a modified designisdeveloped basedonthe
several design calculation and the same is simulated in the
ProCAST software under variable conditions. At the end of
this chapter the results obtained from the numerical
simulation of the modified L type sealing casting are
discussed.
3.1 Pouring time
Pouring time,
For less than 40 Kg
Where,

T = Average section thickness in mm
W = Mass of casting
So,
3.2 Choke area
Choke area:
Where,
W= casting mass in kg
d=mass density of molten metal
t=pouring time
C=efficiency factor
g=acceleration due to gravity mm/
H=effective metal head in mm
So,
3.3 Gating Ratio and Sprue well
Gating ratio = 1:2:1 (sprue: runner: gate)
Choke area A = 201 mm2
Runner area from gating ratio (1:2):
mm2
Ingate area from gating ratio (1:1) = 201 mm2
Sprue well area:
mm2
mm
3.4 Riser
[Note: Constant Canies equation for Grey Cast Iron a = 0.3, b
= 0.03, c = 1.00]
Substituting above values in to Canies equation for grey cast
iron
By trial and error method,
Height of the riser = diameter of the riser = 7cm.

3.5 Pre-processing (the programme reads the CAD
geometry and generates the mesh)
Figure 11 shows the isometric wireframe view of the
modified casting mold used. The dimensions of the same are
given as below,
Length = 300 mm, Width = 300 mm, Height = 120 mm.
The model is drawn and developed in the Ansys Design
Modelers software. The modified model is thenimported for
the meshing purpose. The meshing of the model is carried
out in two steps, first the surface meshing is carried out
followed by the volume meshing of the model. Both the
surface meshing and volume meshing of the model are
shown in Figure 12 and Figure 13 respectively.
Fig -11: Isometric Wire Frame Modified Model of the
Casting Mold
Fig -12: Surface Meshing Of the Modified Model
Fig -13: Volume Meshing Of the Modified Model
3.6 Main processing (addition of boundary
conditions and material data, filling, and
temperature calculations)
After meshing the main processing stagecomesin picture.In
main processing material assignment, boundary condition
and heat transfer conditions from body to mold were given
as per the existing model shown on figure 5, 6 and 7.
3.7 Post processing (presentation and evaluation).
At post processing we got the contours of total shrinkage
porosity, hotspot and misrun sensitivity. In figure 14 we can
clearly see that total shrinkageporosityreducedandpresent
at only few points.
Fig -14: Total Shrinkage Porosity of Modified Model
Figure 15 shows the contour of hotspot on the modified
model, from the figure we may say that modified model has
fewer hotspots on its top surface. Misrun sensitivity of

modified model is shown in figure 16, from the figure we
may conclude thatmodified model norisk misrunsensitivity.
Fig -15: Hotspot on Existing Model
Fig -16: Misrun Sensitivity of Existing Model
4. CONCLUSIONS
In this research, it is proposed to examine a sealing casting
model produced from grey cast iron. For sand casting,
different circumstances are simulated numericallyusingthe
commercial software pro-CAST. Various solidification
performance metrics, including temperature, hotspot, total
shrinkage porosity, and solidification contour, etc.
1. Casting simulation technology has sufficiently
matured and has become an essential tool for
casting defect troubleshooting and method
optimization. It enables quality assurance and high
yield without shop-floor trials, and considerably
reduces the lead-time for the first good samplecast.
2. By moving the trial and error process into the
virtual world and determine the cost of different
design and process options. By minimizing real
world trial and error (and surprises) making
castings right the first time.
3. From above thesis work, we found that when riser
is introduced the shrinkage porosity decreased.
Also by modifying geometry as per the sizes of the
gating system defects like hotspot, misrun and
shrinkage porosity decreased. After all it reduces
the casting rejection rate.
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the solution of one-dimensional phase change
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[9] Babak Kamkaria, H. J. A. (2017). "Numerical simulation
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[10] Feng Liu, “Optimized Design of Gating/Riser System in
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