Quality and yield improvement of ductile iron casting by simulation technique

Abstract Foundries contribute to production of major automotive parts. These foundries now a days suffering from poor quality and productivity due to different parameters of the casting process. Casting quality depends on the solidification process after pouring. Computerized casting modeling and solidification simulation is being extensively used by foundries to design the casting process for manufacturing of castings before castings are prepared or before equipment is constructed or improved. The basic objective of using computerized casting modeling and solidification simulation is to increase the quality of the casting manufactured, both in the existing produced casting and first ever castings made and to reduce cost expenses. The shop floor trials can be reduced effectively by casting solidification simulation and defect free castings can be assured. The casting simulation approaches are based on finite element method (FEM), finite difference method (FDM), finite volume method (FVM). In this paper an attempt has been made to use finite difference method (FDM) and finite volume method (FVM) for casting solidification simulation and optimization of casting gating system to assure maximal yield. Modeling and simulation of Flange is analyzed in this study. The material for the flange is ductile iron and produced using shell molding process. Ductile iron has wide range of mechanical properties suitable for production of automotive parts. The 3D model of flange and gating system is created using CATIA and it is simulated using Solid CAST and Auto CAST-X software’s. The simulation software results will predict the location and level of shrinkage. Optimization of gating system will improve casting yield. This will suggest the modifications needed in gating system.