OPTIMAL RISER DESIGN FOR SAND CASTING BY USING AUTOCAST

Abstract

Casting is one of the oldest manufacturing processes and even-today, it is the first step in manufacturing most of the products, so major emphasis should be given for improvements of this field of manufacturing. Here improvements are in terms of optimization of gating and risering system by some modeling and simulation technique. In this project for optimal designing of gating and risering we use some CAD packages like ANSYs, AutoCAST, etc. For starting of optimization of gating and risering system a computer aided rigging system design approach is given which will are established from old design rules and company experience and an example of system application is also given. As casting simulation has become a powerful tool to visualize mould filling, solidification and cooling, and to predict the location of internal defects such as shrinkage porosity, sand inclusions,, and cold shuts. It can be used for troubleshooting existing castings, and for developing new castings without shop-floor trials. Then in casting simulation feeder design and optimization framework is given, which will lead to best gating design possible and its analysis is also done. At last the simulation can be performed by using several techniques, including Finite Element Method (FEM) and Vector Element Method (VEM), so its mathematical modeling is also given with the application of the method in AutoCAST.