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Metal Casting Technologies : September 2008
TECHNICAL FEATURE Simulation of existing design of component The Fig. 4 indicates the Auto CAST software window, displaying the existing design of component with two exothermic sleeves. The Fig. 5 displays the solidification pattern of the component when used with two exothermic sleeves. Though the solidification pattern for the existing design is found to be satisfactory from the following results, the percentage of yield of the casting is below par. Hence the design can be modified to improve the yield. Problem identification The following are the problems identified in the existing design of casting: ? The casting has a low yield of 63.7 %. ? Difficult and time consuming fettling process due to internal gating system ? Two exothermic sleeve risers are used. ? Unnecessary machining required as risers are located above the component Simulation of modifi ed design of the component After studying and simulating the casting with different of riser locations, a final optimum design has been arrived at. The Fig. 6 indicates the AutoCAST software window displaying the modified design of casting with a single sand riser. The Fig. 7 displays the solidification pattern of the casting when used with a single sand riser. The shrinkage in the AutoCAST software is indicated by means of yellow patches and in this solidification drawing the pattern clearly shows there is no possibility of shrinkage. Implementation of pilot batch Here the above studied, simulated and modified design of casting has been validated with a trial batch. The castings produced in the trial batch has been photographed and shown from Fig. 8 to Fig. 11. Figure 4. Existing design of component with two exothermic sleeves Figure 5. Solidification pattern of the existing design Figure 6. Modified design – single sand riser 78 www.metals.rala.com.au Figure 7. Solidification pattern of the modified design