29-08-2011, 01:00 PM
Quantitative analysis of casting process.pptx (Size: 14.4 MB / Downloads: 216)
Company profile
SUPREME ENGINEERING WORKS is company situated at Pithampur which is an Automobile Ancillary Division of Supreme Groups.
The company produces about 200 automobile components and have a turnover of 30 crores (INR) annually.
The company is No. 1 vendor of VE Commercial situated at Pithampur.
The Company is ISO 9000:2008 certified.
Component display
Shop floor visit
Centre lath operations
Drilling and boring
Vmc operartions
Vmc operations
Project assigned
The project assigned to us was to go through the Sand casting process of upper case selector of EICHER truck GEARBOX.
The task involves
Modeling with allowances
Software simulations
Graphical plots
Pattern design
Final casting
upper case selector
Project time line (gantt chart)
PRODUCTION DRAWING (TOP VIEW)
SIDE VIEW (RIGHT)
SIDE VIEW (LEFT)
MODELLING IN CATIA V5
Structural analysis
Defined loads of 20 N & Applied restraints
Octree meshing
Von misses stress developed (simulation)
Displacements (generated report)
Calculated parameters
Volume of casting = 2.467 x 10 mm3
Volume of shrinkage = 5.5% of original
=13568.5 mm
Casting modulus (V/A)= 25mm
Solidification time=173 sec
Gating ratio = 1:4:2 (Non ferrous )
Mould box dimensions (430x430x120 mm)
Mould box design in NX 7.0 (WIREFRAME)
Geomesh meshing
The tetrahedral element of size 10 mm with a tolerance of 0.1 was chosen as mesh type.
The GEOMESH generated the STL file which was the mesh file of mould box containing the cavity.
The STL meshed file was then transferred to the PROCAST software.
In PROCAT the re-meshing of mould was applied to fix the bad triangles and intersections of STL file.
Procast meshing
Detailed meshing parameters
Parameters defined
Material assigned :-
Mould - Green sand
Metal - Aluminum
Process
Gravity i.e. -9.81 m/s2 in X-direction
Initial conditions
Temperature :- Green sand (35 C)
Aluminum (700 C)
The problem was solved in 2000 steps
Mould box temperature after 1304 seconds
Solidification plots after 1211 seconds
Temperature vs time plot
Fraction of solid vs time plot
Pattern material & allowances
Wood was chosen as the pattern material as it is easily available, low weight and easily shaped
Shrinkage allowances
1.6mm per 100mm
Draft allowance
2mm per 100mm
SIMULATION
Sand preparation
silica sand (SiO2), 75 to 85%
bentonite (clay), 5 to 11%
water, 2 to 4%
anthracite (0 to 1%)
Mould preparation
Pouring
The pouring was done at 703 C of aluminum and measured from DIGITAL thermometer