Papers by Keyword: Sand Casting

Abstract: Casting is one of the most commonly used manufacturing method for geometrically complex product. Among the casting technologies, sand casting is often found in application. Beside the advantages of the sand-casting process, it also has a drawback that is often encountered, namely product defects. Product defects can be caused by a lack of attention to sand casting parameters. This work aims to minimize those defects, including porosity defects, shrinkage defects and incomplete defects by optimizing process parameters using the Taguchi method. The identified sand-casting process parameters include gating location, riser location, molding conditions and pouring temperature with each parameter consisting of 3 levels. This research using the fractional factorial L₉ (3⁴). Data processing is carried out by analysis of mean (ANOM) to obtain plot effects. The results showed that the optimal combination of parameters that resulted in shrinkage, porosity and minimal incomplete defects were at gating location level 2, riser location level 1, mold condition level 2 and pouring temperature level 3. The results of the comparison before and after optimization were an increase of 0.77, where previously it was 1.30 to 2.07 based on normalized data.

Abstract: In Engineering Schools, labs for teaching forming processes by means of material conservation methods are generally equipped with the appropriate equipment and tools to exemplify the theory received in class. However, the use of simulation techniques to complement the formation is not usually widely extended, since their learning is not usually trivial.One of the material conservation forming processes is sand casting. This process is of great educational significance, since the theory that defines it sets the basis for understanding other related moulding processes. In this context, the use of simulations of the moulding process allows the visualization of practical examples, helping to explain more clearly the theoretical information explained in class.Therefore, in this research a simulation assisted analysis has been developed using the Inspire Cast by Altair software, of teaching parts made in sand casting. First of all, students have been shown by means of simulations, the defects that can be originated in a part manufactured by sand casting. The study has been carried out by redesigning the risers involved in the distribution system of the process, by means of the Chvorinov's rule.Finally, a series of conclusions have been achieved, among which the following one stands out: if the functional performance of the part manufactured by sand casting is to be taken into account, the cooling modulus criterion must be selected for the design of the riser. Although, in principle, the material required for moulding is much larger, the defects generated in the part will be considerably reduced.

Abstract: Aluminium-copper alloys are known for their very good strength at high temperature .Addition of copper improves the strength at high temperatures due to precipitation strengthening. Fluidity in casting is the major factor which affects the cast quality of the final components. Addition of Silicon with copper in Aluminium improves fluidity and finally quality of the cast components. But presence of Silicon adversely affects the strength at high temperature. In the present work cooling curve analysis of Al-Cu alloy (without Silicon) is done for different wt% of copper addition. The current study for Al-Cu alloy is based on sand casting method as it is one of the cost effective manufacturing method. Cooling curve obtained from the simulation results used to predict the fluidity, microstructure of the alloy when copper wt% is varied. Predicted microstructure and grain structure from the cooling curve goes well with the microstructure studied from shop floor casting .In the present work “Z-cast” casting simulation software is used for casting simulation. Among three different alloy composition studied aluminium with 8% copper gives the best results when compared on the basis of grain size .But fluidity analysis reveal poor fluidity for the alloy having 8 wt% of copper. The current analysis helps to study the optimum aluminium –copper alloy composition that can be used in high temperature applications.

Abstract: 3D printing has been recognized to be such a game-changer in manufacturing that it has now permeated virtually every aspect of the industry, including mould and die casting. A thorough examination of 3D printing's past, present and future in the business is provided here. Casting procedures may be enhanced or drastically altered by 3D printing. The design of goods, assemblies, and parts will be transformed by 3D printing, which is more than just a manufacturing technology. With the aid of 3D printing, sand casting is a technique that can make complex components out of almost any metal alloy at a reasonable cost. Using this integration, producers may build massive components in the least amount of time. It has also established a distinctive place in other casting elements; Examples include the ceramic shell, sand mould sand core, and wax pattern, we'll learn more about sand casting and 3D printing this week.

Abstract: In the current advancing world, operability and ease in processability of a material define its selection criteria for the intended applications. Hence, the industrial applications requiring high temperature sustenance, strength and corrosion resistance desperately demand the materials which employ simple processing in an economical way. Contemplating last few decades, it has been discovered that industries like petrochemical, power generation, nuclear energy, etc. greatly relied on nickel-based alloys till Fe-Ni-Cr based alloys were not introduced. The usable components are obtained either in cast or wrought form as per requirements. Fully killed alloy, developed under controlled conditions with some precautions during the casting process can lead to sound casting. The current study adopts a novel preliminary approach to control the quality of cast UNS N08120 material and minimize the possibility of defect generation. The possible reasons behind cast defects and how they transform into intrinsic defects have also been discussed. Calcium-based fluxes are introduced to molten metal as a degassing agent for the elimination of lighter impurities and entrapped gases. By the addition of quicklime (CaO) as a flux material during the sand casting process, an attempt has been made to reduce the presence of gases and impurities by more than 80%.

Abstract: The bicycle frame produced through the metal casting process by recycling aluminum alloys can be an environmentally friendly alternative solution. Mold types and gating systems used generally affects the quality of the casting product. In this experiment, the effect of gating number and riser type variations (for sand binder) observed on casting defects, hardness, and impact value. Subsequently, chemical composition and microstructure of recycled aluminum metal from bicycle frames produced through sand mold casting are also evaluated. Three types of risers are bentonite, water glass, and furan resin. The results indicate that mold with two gating system has a low porosity as casting defects. The cast-bike frame produced using furan resin reaches the highest hardness value of 46 HRB compared to water glass and bentonite as the binder of sand-molds. The impact test observes 3.9 J carried out by the ASTM E23 sample at room temperature.

Abstract: Sand casting is one of manufacturing process that still exist today. Numerous products are produced to serve industrial and domestic use. Defect could lead to product performance, and unfortunately inevitable in a casting process. This paper aim to investigate typical defect resulted from sand casting process. An aluminum cooling fan was selected as the model since it has complicated shape with different thicknesses. The casted fan was investigated under photo micro for defect analysis. Porosity, gas inclusion, pinhole, and shrinkage were found as the common defects occured at different part of the fan.

Abstract: The use of aluminum castings in the automotive industry has increased dramatically over the past two decades. The Al-Si system forms the basis of many important casting alloys, LM 0, LM 2, LM 4, LM 5, LM 6, LM 12, LM 13, LM 24 and LM 26 are the major cast alloys used in aerospace casting (e.g., fuel pump connectors) and premium automotive castings (e.g., suspension arms). The driving force for this increased use is vehicle weight reduction for improved performance, particularly fuel efficiency. In many cases the mechanical properties of the cast aluminum parts are superior to those of the cast iron or wrought steel parts being replaced; however, in some applications, defects in the cast microstructure undermine performance characteristics.

Abstract: The development of the automotive industry brings impact of increasing use of aluminum for vehicle components that will ultimately produce more aluminum waste. If it is not addressed properly, it will be a serious problem for the environment. One of the solutions is to recycle the waste of drum brake to be a raw material for motorcycle accessories brake handle. The process of making motorcycle brake handle using the sand casting method can be done by varying the temperatures of casting molten metal which are at temperatures of 650°C, 700°C and 750°C. Furthermore, the testing of the mechanical properties and microstructure of the resulted product is done. The result shows that motorcycle brake handle required high impact strength in which the highest impact strength was 0.011 Nm/mm2 that was obtained when temperature of casting was 700°C.

Abstract: Bicycle frames on the market are generally made from a pipe connected by welding process. Bicycles are made by big companies, because it requires forming technology of raw materials for the pipe production and complex welding technologies. In order to reduce the dependence on raw materials and pipe welding processes, an alternative technology for bicycle frame manufacturing process is investigated. This study is aimed to examine the use of casting technology in the manufacturing process of bicycle frame. Production of bicycle frames in limited quantities is possible by using the casting process. To achieve these objectives, it is necessary to redesign the bicycle frame suitable for the casting process. Prototypes have been produced and the first bike is in the testing phase. Initilly , the bicycle is relatively heavy (7 kg). The optimization of the design reduces to a light and strong frame. The frame has a weight of 3.74 kg. The prototype of the frame has been succesfully casted by sand casting method.