Quality casting of motor body using design of experiment and casting simulation

Abstract

Solidification of metals stands as marvel of ultimate significance for metallurgists, casting engineers and physicist which hampers the quality of castings, material yield and cycle time. Method of solidifying in casting is intricate in natural surroundings hence the process replication is mandatory in business before it is actually enforced. Volumetric contraction allied with solidifying of liquefied metal causes defects viz: shrinkage porosity, sink and cavity. Casting defects are decreased through casting simulation software and an intellectual feeding technique. Generally, gating system controls the velocity of molten metal that affects turbulence and flowability of casting. In this research, a challenge is taken to remodel a gating system by design of experiments (DoE) and casting solidification simulation framework ('e-foundry' - a web resource with casting simulation facility) and validation of results based on experiments performed in Krislur Castomech Pvt. Ltd, Bhavnagar, Gujarat, India for minimum shrinkage porosity defect in casting. [Received 29 October 2015; Revised 29 April 2016; Accepted 12 May 2016[