Numerical Optimization of Grey C.I. Casting using Simulation

Foundries represent an important sector of the manufacturing industry and these foundry industries in developing countries suffer from poor quality and productivity due to number of process parameters involved in the casting process. Even in a completely controlled process, defects in casting are observed and hence casting process is also known as process of uncertainty which challenges explanation about the cause of casting defects. In sand casting process number of defects occur due to the wrong methoding of gating system, improper location of feeder and material properties. Production of this material need to be simulated and visualized it for mould filling, solidification, cooling and internal defects. In this paper numerical simulation technique has been used to study defects in sand casting related to methoding. Numerical simulation is useful tool for Casting in getting high quality castings and reducing product cost and rejection. The numerical simulation trial have been taken on current existing system and results showed that shrinkages, blow holes on casting. After modification of gating system, the simulation results showed that new gating system gives maximum yield as well as free from defect. Keyword Simulation, Casting defect, Methodology, Yield improvement.