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Metal Casting Technologies : September 2008
TECHNICAL FEATURE Existing Design 1. Modified Design 2. 3. 4. 5. Two costlier exothermic sleeves are used. Yield is low (63.7 %). Fettling is difficult due to internal gating design. Total cost of component is high. Table 2. Comparison of Existing and Modified Designs of the Piston Results The modified design developed with the aid of virtual simulation package AutoCAST has been found convincing and has yielded results as listed in Table 2. REFERENCES Conclusion This paper attempts to discuss the advantages of using virtual manufacturing efforts through computer integrated manufacturing, in foundries to improve the yield. The modification of casting design with the aid of Virtual Simulation Package namely AutoCAST has improved the yield from 63.7% to 72.4%. The total savings for piston casting sums upto Rs. 89.97/ piece. Also the productivity of the piston casting has been increased by 120 molds against 80 molds for the same production time. This work can be extended for all the castings in any foundry, with the united support of academic as well as industries through Industry Institute Partnership Programmes. The only constraint is the availability of the software and the operational knowledge of the software. In order to overcome such constraints the government should facilitate the establishment of foundry clusters across the country and provide the necessary infrastructure to make the foundry globally-competitive. Thus the Virtual Simulation of Castings using AutoCAST has yielded real time benefits to the foundry by eliminating of huge loss of time resulting due to trial and error approach. ¦ 82 www.metals.rala.com.au 1 Ravi.B, et al, Survey of Computer Applications in Indian Foundry Industry: Benefits and Concerns, Proceedings of 53rd Indian Foundry Congress, Kolkata, January 2005. 2 Arno Louvo., Casting Simulation as a Tool in Concurrent Engineering, Proceedings of International ADI and Simulation Conference, Espoo, Finland, May 28-30, 1997. 3 Campbell.J, Castings, Elsevier Butterworth Heinemann Pvt Ltd, Burlington, MA, 2003. 4 American Society of Metals, Casting Design Handbook, 1962. 5 Richard W Heine, Carl L Loper and Philip C Rosenthal, Principles of Metal Casting, Tata McGraw Hill Publisher, New Delhi, pp. 217-240, 1976. 6 Jain.P.L, Principles of Foundry Technology, Tata McGraw Hill Publisher, New Delhi, pp. 229-250, 1987. 7 Campbell.J, Casting Practice – The Ten Rules of Castings, Reed Elsevier Pvt Ltd, India, 2004. 8 Michael A. Gwyn., Cost Effective Casting Design: What Every Component Designer Should Know, Journal of Foundry, pp, 13-28, Nov/ Dec, 2006. 9 Myskowski.E.T, et al, A simplified method for determining riser dimensions, Trans. AFS, Vol. 63, pp. 271, 1955. 10 Ravi.B, Metal Casting – Computer Aided Design and Analysis, Prentice Hall of India Pvt Ltd, New Delhi, 2005. Single cheaper sand riser is used. Yield has improved (72.4 %). Fettling is made easier with external gating design. Total cost is reduced. Rs. 89.97 per component is saved.