Shrinkage Elimination in Casting of GG30 Grade Cast Iron Impellor by using Pro-cast Software& Finite Elemental Analysis by Meshcast Software

There are 100+ submersible pump manufacturers in Rajkot Engineering Cluster. So, there are 100 plus foundry engaged in casting of cast iron impellor for submersible pump. They face shrinkage defect after casting and about 10 % rejection is because of shrinkage.[1] So in order to reduce this defect casting simulation software is very helpful. By using Pro-Cast simulation software mould of impellor is imported in Pro-Cast software and by applying sand mould condition, pouring temperature, pouring time etc. are put into the software, and finally result shows the areas of impellor where shrinkage chances are more.

Defect Analysis and Process Parameter Optimisation in Sand Casting

M/s. Boparai Metals, a small scale industry situated in Industrial Area, Mohali, Punjab is manufacturing and supplying automotive and non automotive component to tractor companies in Punjab and aiming to provide the best solutions. The company is facing the problem of castings defects i.e. porosity, hot spot and shrinkage in cooler plate during the Sand Casting process. In this work, the study of existing process was done to find the root cause of the problem. Three dimensional gating system of cooler cover plate were modified by using UG– NX software. The models were imported using ADSTEFAN software for simulation of SAND-CASTING process. Based on the specification of cooler cover plate material, cast iron moulds in the green sands and input process parameters; design calculation of casting model was undertaken. Three case studies i.e. analysis based on the solidification method, were carried out for defect analysis of casting component and simulation study was done for process parameter optimization using ADSTEFAN software. It was observed that molten metal enters at critical location of cover plate causing turbulence in metal flow and solidification was not getting achieved in the directional way, thereby resulting in shrinkage defect. The shrinkage defect was removed by providing risers at proper location.

Overview of the Injection Moulding Optimisation for Shrinkage Defect

The injection moulding process in manufacturing plastic material has become a worldwide used for more than 100 years. The used can be seen everywhere instead of became a daily used product. The complexity of the process makes it difficult to handle but the big production makes it possible to happen. The entire process not just involve the difficult cycling process, but the involvement of the materials which pertaining many types of characteristic which considered to. Every big production need a quality production product with suitable cost and time efficiency. Eventhough, alongside the process, many defects can be detected by the physically seen marks. Many people especially from the expert’s field are trying to minimise as much as they can to reduce the defects so that the residual cost can be minimise. One of the way to overcome the problems is by simulation before the real product is being produce. The simulation is made by two classes of types which classical and non-classical method. Either both of the method gave good result but it still not reaches a perfect solution. In this study, the optimisation method of non-classical and classical are used to minimise the shrinkage defects at the thick plate part.

Investigation of Shrinkage Defect in Castings by Quantitative Ishikawa Diagram

Metal casting process involves processes such as pattern making, moulding and melting etc. Casting defects occur due to combination of various processes even though efforts are taken to control them. The first step in the defect analysis is to identify the major casting defect among the many casting defects. Then the analysis is to be made to find the root cause of the particular defect. Moreover, it is especially difficult to identify the root causes of the defect. Therefore, a systematic method is required to identify the root cause of the defect among possible causes, consequently specific remedial measures have to be implemented to control them. This paper presents a systematic procedure to identify the root cause of shrinkage defect in an automobile body casting (SG 500/7) and control it by the application of Pareto chart and Ishikawa diagram. with quantitative Weightage. It was found that the root causes were larger volume section in the cope, insufficient feeding of riser and insufficient poured metal in the riser. The necessary remedial measures were taken and castings were reproduced. The shrinkage defect in the castings was completely eliminated.