PARAMETRICAL ANALYSIS OF POROSITY IN CASTING

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, porosity is one of the serious problems observed in foundries. The variations of porosity with pouring temperature, pouring time and types of gating system is analysed in this work. The experimental results are validated with AUTOCAST and DEWINTER MATERIAL PLUS software. Here improvements are in terms of optimization of gating and risering system by some modelling and simulation technique. In this project for optimal designing of gating and risering we use some CAD package like AUTOCAST. 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. 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 AUTOCAST and its mathematical modelling is also helpful for analysing gating system, riser and part model.