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Determination of Optimum Casting Process Parameters in Product Development through Solidification Simulations


Affiliations
1 Mechanical Engg. Dept., Deccan College of Engineering & Technology, Hyderabad, India
2 Mechanical Engg. Dept., National Institute of Technology, Warangal, India
3 Mechanical Engg. Dept., Jawaharlal Nehru Technological University, Hyderabad, India
     

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Integrating statistical techniques and simulation technologies and their simultaneous usage allow shortest product development periods, required casting quality, on the whole, improves economic efficiency. Casting solidification simulations are conducted for a stepped block of aluminum alloy casting to study the effect of pouring temperature and chill parameters on porosity formation and cooling rate in a sand casting. Taguchi methods are used for experimental simulations with a four factor, three level L9 orthogonal array. Porosity and cooling rate are recorded from a three-dimensional finite difference solidification simulation program as response functions. Statistical techniques are used for analyzing the effect of process parameters on porosity and cooling rate In the cast component. Numerical optimization techniques are presented with multivariable optimization for predicting the factor levels for minimization of porosity and maximization of cooling rate. A confirmation run is carried out to compare the predicted levels of process parameters with final simulation run.
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  • Determination of Optimum Casting Process Parameters in Product Development through Solidification Simulations

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Authors

D. Hanumantha Rao
Mechanical Engg. Dept., Deccan College of Engineering & Technology, Hyderabad, India
G. R. N. Tagore
Mechanical Engg. Dept., National Institute of Technology, Warangal, India
G. Rangajanardhan
Mechanical Engg. Dept., Jawaharlal Nehru Technological University, Hyderabad, India

Abstract


Integrating statistical techniques and simulation technologies and their simultaneous usage allow shortest product development periods, required casting quality, on the whole, improves economic efficiency. Casting solidification simulations are conducted for a stepped block of aluminum alloy casting to study the effect of pouring temperature and chill parameters on porosity formation and cooling rate in a sand casting. Taguchi methods are used for experimental simulations with a four factor, three level L9 orthogonal array. Porosity and cooling rate are recorded from a three-dimensional finite difference solidification simulation program as response functions. Statistical techniques are used for analyzing the effect of process parameters on porosity and cooling rate In the cast component. Numerical optimization techniques are presented with multivariable optimization for predicting the factor levels for minimization of porosity and maximization of cooling rate. A confirmation run is carried out to compare the predicted levels of process parameters with final simulation run.