Gating System Design and Solidification Simul...

Gating System Design and Solidification Simulation for Steel Casting using CAE Software

Author Name : Rama Nakshatra, Guguloth Jeevan, Jilla Anshu Prasanna, N. Veman Reddy

DOI: https://doi.org/10.56025/IJARESM.2023.11723207

ABSTRACT

The casting process is widely employed in various manufacturing industries; however, accurately simulating the filling and solidification of molten metal remains a complex and challenging task for traditional methods. To address the need for a faster, more reliable, and user-friendly approach in large-scale industrial applications, computer-aided casting design and simulation have emerged as an alternative. Casting simulation software enables the analysis of mold filling and solidification processes, playing a crucial role in the paradigm shift from trial-and-error methods to computer-aided simulations. This study focuses on Gating System Design and Solidification Simulation for Steel Casting using Computer-Aided Engineering (CAE) software. The investigation reveals a direct relationship between defects such as shrinkage, micro porosities, and improper solidification with gating and riser systems. Empirical relations are employed to calculate the gating system, and a 3D solid model of the casting and gating system is developed using Solidworks software. Initially, simulations are conducted without a riser and chill, followed by simulations without a riser but with a chill. Both simulations exhibit shrinkage and porosity issues. To enhance the casting yield, the riser volume is calculated using the modulus method, and a third simulation incorporating a riser demonstrates the elimination of shrinkage and porosity defects. Subsequent simulations involve decreasing the volume of risers, leading to a 2.32% improvement in casting yield. The findings of this study underscore the significance of computer-aided casting simulation in the new product development paradigm, enabling comprehensive modeling of entire casting processes. By employing CAE software, engineers can optimize the design of gating systems, minimize defects, and enhance the overall casting yield. This research contributes to the advancement of steel casting processes, offering valuable insights for manufacturers seeking to improve the efficiency and quality of their production techniques.

Keywords: Casting process, simulation, computer-aided design, gating system, solidification, steel casting, CAE software, defect analysis, shrinkage, porosities.