CastingDesignandSimulation

2012

CastingDesignandSimulation

Prof.B.Ravi,I.I.T.Bombay

Feedability

Prof.B.Ravi,I.I.T.Bombay

Controlledprogressivedirectionalsolidificationathighestyield
Nohotspotsinsidecasting

PerfectFeederDesign

Feedershape anddimensions(modulus)

Feedpathsconverginginfeeders
Feederlocation&position,Neckconnection

Slowcoolingofconnectingsections

Feedability
FeederSize
NeckSize
FeedPath

Feedaids,Partmodification(padding/fins)

Optimalfeedingefficiency
Feederspercasting,castingsperfeeder

Feederyield
EFoundry,I.I.T.Bombay

FeederModulus(TopFeeders)
Rectangular

Cylindrical

Prof.B.Ravi,I.I.T.Bombay

FeederModulus(SideFeeders)
Rectangular

SphericalTop

CylinderTapered

Prof.B.Ravi,I.I.T.Bombay

SphericalBottom

D =1.5W,H=1.5D
DN =60,HN =50

H=1.5D
DN =60

H=1.5D
DN =60

Blind

0.15D

0.21D

0.23D

Open

0.10D

0.14D

D =1.5W,H=1.5D
DN =60,HN =50

H=1.5D
DN =60

H=1.5D
DN=70

Blind

0.16D

0.19D

0.24D

Open

0.12D

0.15D

0.18D

Assumenoheattransfer(cooling)fromfeederbottom

FeederModulus

Assumenoheattransfer(cooling)fromfeederneckregion

Prof.B.Ravi,I.I.T.Bombay

FeederSize

Prof.B.Ravi,I.I.T.Bombay

STEP1: Ifshapeiscomplex:
F1

subdivideintosimpleshapes,

A
B

Principle:

STEP2:DecidefeederH/D,
F1

calculatemodulusforeach.

Metal

k (min)

CalculateitsHandDbasedon

A
B

Example:

Vol.
(cm3)

250

100

60

Mf=Vf /Af =0.38Df

Area
(cm2)

225

95

94

Df =3.5cmHf =1.5Df =5.3cm

Mod.
(cm)

1.11

1.05

0.64

Feedersolidifiesaftercasting

GreyIron

1.2

Initial:

f >c Mf >Mc Mf =kMc

Ductile Iron

1.2

Mf =kMA=1.2x1.11=1.33cm

Steel

1.3

Aluminum

1.2

Copper

1.3

M=V /A
V =volumeofshape
A =heattransferarea

(c)B.Ravi,IITBombay

modulusvalue.

CastingDesignandSimulation

2012

FeederSize

Prof.B.Ravi,I.I.T.Bombay

FeederSizeEvaluation

Prof.B.Ravi,I.I.T.Bombay

STEP3:Revisefeederdesign
F2

NegativeGradient=>PoorFeeding

consideringenhancedmodulus

A
B

ofconnectedpart

Vol.
(cm3)

250

100

60

Mf=Vf /Af =0.38Df

Area
(cm2)

175

95

94

Df =4.5cmHf =1.5Df =6.8cm

Mod.
(cm)

1.43

1.05

0.64

Revised:
Mf =kMA=1.2x1.43 =1.71cm

CoolingSurfaceArea

Prof.B.Ravi,I.I.T.Bombay

Lowheattransferfrominnerfaces

Effectivemodulus
offeederneckis
1020%higher

d>0.7D
100%coolingfromcore

Layout1

Layout2

FeederNeckDesign

Prof.B.Ravi,I.I.T.Bombay

Feedermodulus>adjacentcastingsectionmodulus
Mfeeder >Mneck
1Mneck >Mhotspot
2 Mneck =Mhotspot
3 Mneck <Mhotspot

11

0.7D>d>0.5D
50%coolingfromcore
d

d <0.5D
0%coolingfromcore

Notchneck

FeederNeckDesign:Exceptions

Prof.B.Ravi,I.I.T.Bombay

Greyandductileirons:graphitisationatendofsolidification:
volumetricexpansioninhardmoldsreducesfeedrequirement.

Idealdesign:feedersuppliesfeedmetalinthebeginning,
thenshutsoff(byfreezingofneckattheappropriatetime).
Mfeeder /Mhotspot =1.1(forGI),1.2(forDI)
Mfdneck /Mhotspot =0.8(forGI),0.9(forDI)

Effectivemodulusofneck
isgreaterthancalculatedvalue
duetoheatingaroundneck.

FeedingDistance

Prof.B.Ravi,I.I.T.Bombay

Platetypecastings,thicknesst,shortfreezingrangemetal
Maximumdistanceincastingfreeofshrinkagedefect:

4.5t

Max.Dist.

Max.Dist.

4.5t

4t

t
Max.Dist.
4.5t+50mm

Max.Dist.
9t+100mm

t
Chill

(c)B.Ravi,IITBombay

Chill

CastingDesignandSimulation

2012

FeedingPressure

Prof.B.Ravi,I.I.T.Bombay

SectionfedbyFeederF1 andF2

SectionfedbyFeederF3

F1

ReversedPr.Gradientcausing
flowfromcastingtofeeder

FeedingPressure

Prof.B.Ravi,I.I.T.Bombay

F2 IscorrectlyventedandeffectsonsectionS3 andS4.
F3 Isnotvented=>buildupofgas =>lowpressure infeeder=>
causingmetalflowsfromS 8toF8=>causingrupture at
weakpointinS8, thuscausingamassivecavityatS8.

F1

CorrectlyVented

S9
S1
S3

F2

S4

F3

S9
NotVented

S1
S3

F2

S4

Surface
Rupture

F3

S8

S8

S2

S2
S5

S6

Summary

Prof.B.Ravi,I.I.T.Bombay

Directionalsolidificationleadstoperfectfeeding
Mfeeder >MNeck >Mcasting toensure feeding
VolumetricexpansioninFGironreducesfeedrequirements

S6

S5

S7

[Adaptedfrom:Castings,J.Campbell]

S7

[Adaptedfrom:Castings,J.Campbell]

Exercise

Prof.B.Ravi,I.I.T.Bombay

Thefollowingfourfeedershaveequalvolume.Arrange
theminincreasingorderofmodulus(solidificationtime).
A

D=10
H=15

D=10.4
H=15.6

D=10.6,L=7
H=15.9

D=11.25
B=3.75,H=16.8

Highest
modulus

Allunitsincm

Metalflowcanbeundergravity,pressureorvacuum
Suitableforintricatepartswithinternalfeatures
(significantcostsavingcomparedtomachining).

Least
modulus

(c)B.Ravi,IITBombay