INDEX

Chapter No. Title Page No.

1 Introduction 1
1.1 Introduction 1
1.2 Purpose & Significance of the Study 1
1.3 Casting Process in Foundry 1
1.4
1.5
Process Flow iagra! in a Casting Industry
Considerations for Selecting a Casting Process
3
3
1."
Solidification Pheno!ena of Co!!on Cast
#etals
5
1.$ %d&antages of #etal Casting 5
1.' Significance of Casting Industry "
1.( )*+ecti&e of the Study "
1.1, Scope of Study "
1.11 Pro*le! Identification $
1.12 #ethodology of -or. $
1.13 %&erage co!position of F/ 2", /rey Cast Iron '
1.14 0enefits of F/ 2", /rey Cast Iron '
1.15 Co!plete Casting Process with 12uip!ent3s
4sed
(
1.1" Casting efects 25
1.1".1 Shrin.age Ca&ities 2"
1.1".2 0low 5oles and Porosity 2"
1.1$ %6S7S Software 2"
1.1$.1 Preprocessing 2$
1.1$.2 Solution 2'
1.1$.3 Post8Processing 2(
2 9iterature :e&iew 3,
2.1 Casting Industry 3,
2.2 Casting efects and its %nalysis 31
2.3 :educing :e+ection in Castings using Si!ulation
#odels
32
2.4
2.5
4sage of Co!puter %pplications in Foundry
Conclusion
33
35
3 Para!eters In&ol&ed in Solidification of Castings 3"
3.1 /ating and :isering in Casting 3$
3.2
3.3
:isering
Casting Plate i!ensions
3$
3'
3.4 :iser 6ec. ;/ates< 3(
3.5 :iser 6ec. i!ensions 3(
3."
For!ulas In&ol&ed for Calculating the :iser
6ec. i!ensions
3(
3.$ Calculation of :iser 6ec. i!ensions 4,
3.' =he 0asic :e2uire!ents of a Feeder Syste! for a
Casting
41
3.( :iser Shape 41
3.1,
3.11
Calculation of :iser i!ensions
:iser i!ensions
42
43
4 #ethodology 45
4.1 Co!puter Si!ulation 45
4.2 %ssu!ptions #ade uring Si!ulation 45
4.3 Pre8Processing 4"
4.3.1 efine 1le!ent and )ptions 4"
4.3.2 efine #aterial Properties 4"
4.3.3 efine #odel /eo!etry 4"
4.4
4.3.4 %pplying 0oundary Conditions> 9oads
Solution
4'
4'
4.5 Solidification Si!ulation 4sing %6S7S
Software
4(
4.$ :esults )*tained fro! Co!puter Si!ulation 5,
4.' Cooling Cur&es 51
4.( 1ffects of Feeder Configurations on
Solidification in Casting of Plate
51
4.1, :esults )*tained fro! 5 6odes 54
4.11 Inference 55
5 =heoretical ?erification 5"
5.1 Introduction 5"
5.2
5.3
5.4
5.5
5."
Calculation of Solidification =i!e
Solidification =i!e of Cast Plate
Solidification =i!e of :iser
Caine3s =heoretical %nalysis of Finding Sound
Casting
Calculation of Free@ing :atio & ?olu!etric
:atio
5"
5'
5'
5(
5(
5.$ Inference ",
" 1Aperi!ental ?erification "1
".1 Introduction "1
".2 1Aperi!ental Procedure "1
".3 =ensile Strength =esting with Speci!en "3
".4
".'
5ardness =esting
Inference
"4
"5
$ Conclusion ""
:eferences "$
LIST OF FIGURES
Figure No. Name Page No.
1.1
1.2
Cross Section of =ypical Casting
Process Flow Chart
2
3
1.3 #ethodology of -or. $
1.4 =ypes of Pattern 11
1.5 #oulding Sand and Core Sand 12
1." 0ellows 13
1.$ 5and Cleaner 14
1.' 5and :a!!er 14
1.( Floor :a!!er 14
1.1, 5and :iddle 15
1.11 Sprue Pins 15
1.12 =rowels 15
1.13 /ate Cutter 1"
1.14 Sho&els 1"
1.15 Flas. 1"
1.1"
1.1$
Pattern Placing
Parting Powder Sprin.ling
1$
1$
1.1' Pac.ing #ould 0oA with Sand 1'
1.1( Sand :a!!ing 1'
1.1(.1 9e&elling Sand Filled rag 1'
1.2, ag is turned 1(
1.21 Placing the Cope 1(
1.22 #a.ing Pouring 0asin 2,
1.23 Creating /ate Path 2,
1.24 Pattern :e!o&al 4sing Spi.e 21
1.25 Creating ?ents 21
1.2" #ould :eady for Pouring 22
1.2$ #olten #etal Pouring 22
1.2' Co!plete #ould 23
1.2( 0efore and %fter Shot 0lasting 24
1.3, Fettling Process 25
1.31 #a+or Casting efects 25
3.1 Casting Plate 3'
3.2
3.3
:iser 6ec. i!ensions ;Side and =op ?iew<
Feeder -ith 5e!ispherical 0otto!
3(
44
3.4 1Aisting Feeder syste! and Proposed Feeder esign 44
4.1 Casting #odel I!ported into %6S7S Software in
.iges For!at
4$
4.2 #odel of Casting %fter #eshing 4$
4.3 Solution )*tained Fro! %6S7S Software 4'
4.4 Cooling Cur&e for :iser of ia!eter ",!! &
5eight ',!!
52
4.5 Cooling Cur&e for :iser of ia!eter "5!! &
5eight '5!!
52
4." Cooling Cur&e for :iser of ia!eter $,!! &
5eight (,!!
53
4.$ Cooling Cur&e for :iser of ia!eter $5!! &
5eight (5!!
53
5.1 Caine %nalysis ",
".1 Casted Plate "2
".2 i!ensions of the =ensile =est Speci!en "2
".3 #achined =ensile =est Speci!en "3
".4 4lti!ate =ensile Strength =esting "3
".5 5ardness =esting "4
LIST OF TABLES
Tale No. Name Page No.
1.1 %&erage co!position of F/ 2", grey cast iron '
3.1 Casting Plate i!ensions 3'
3.2 :iser i!ensions 43
4.1 =her!o Physical Properties of Cast #etalB
F/ 2", /rey Cast Iron
5,
4.2 =e!perature ?ariations at ?arious 6odes 54
4.3 =e!perature ?ariations at Selected 6odes 54
5.1 Solidification =i!e of Cast plate 5'
5.2 Solidification =i!e of :iser 5'
5.3 Free@ing :atio ;F:< ?s ?olu!etric :atio ;?:< 5(
".1 1Aperi!ental :esult )*tained "3