Research & Reviews: Journal of Material Sciences
MenuISSN:2321-6212
ISSN:2321-6212
K Koushik, Nataraj J R, Krishna M and Karthik S B
R V College of Engineering, India Dayananda Sagar University, India
Posters & Accepted Abstracts: Res. Rev. J Mat. Sci
There is renewed interest in sand casting components due to new technological developments and simulation techniques. Several researchers have developed algorithms and softwares to simulate casting process and predict defects such as porosity, blow holes, cracks and cold shuts. The objective of this paper is to obtain defect free counter weight casting (component) by best gating system based on flow simulation. CAD model of one such critical component counter weight is done in ADSTEFAN software where process parameters like weight, type and temperature of the molten metal and no-bake sand are given as input and flow simulations of three iterations of different gating systems to obtain defect free casting are performed. Actual castings for three gating systems are developed and results (defects) are compared. From first principle, the sizes of risers and flow offs are calculated with cross sections being either rectangular/cylindrical/conical shapes. Pressurized gating system is considered with a D: R: I (Down sprue: runner bar: Ingate) ratio is 1: 1.6: 0.9. Due to improper location of ingates and risers shrinkage formation is about 8-11% and 11-15% by volume in first and second iterations respectively. Installing of sleeve risers (at the point prone to casting defects) at hot spot where solidification ends results in reduction of volumetric shrinkage by 98%. Time taken to fill the mould cavity by molten metal is about 24-26 s for all three iterations. Visual inspection of actual counter weight casting of 1st and 2nd iteration showed the formation of shrinkages, cold shuts and surface blow holes and 3rd iteration showed no defects. Hence, third iteration gating system was recommended for manufacturing. Recent Publications 1. K Koushik (2018) Design, Impact, Simulation Studies of Tubular Chassis of an all-terrain Vehicle Metals, Materials and Manufacturing Conference held in Singapore March 12-13th 2018, I: 10.5176/2251-1857_M318.12. 2. K Koushik and Nataraj J R (2018) Impact studies of Roll cage of All Terrain Vehicle. International Journal of Engineering, Global Science and Technical Forum.
K Koushik is pursuing his 3rd year Mechanical Engineering at R V College, Bangalore, India. He is currently working as a Chassis Engineer in Team Helios Racing. He is also working on alloy materials for high temperature applications. He has presented his technical paper on Chassis of an ATV at M3 2018 Conference, Singapore.
E-mail: koushikkosanam1897@gmail.com