Summary Casting is a manufacturing process to make complex shapes of metal materials; during mass production, we may experience many defects, such as gas porosity, pin holes, blow holes, shrinkages and incomplete filling that may occur in sand casting. Porosity is one of the defects most frequently encountered in ductile iron casting. Porosity impacts cost by scrap loss and limits the use of cast parts in critical high strength applications. The amount of porosity is closely related to the parameter of sand casting process. The gating/riser system design plays a very important role for improving casting quality. Many researchers reported that 90% of the defects in casting are obtained only because of improper design of gating and feeding system. The main objectives were to study the existing design of gating and feeding system, to optimize the gating and feeding system using Auto-CAST X1 casting simulation software, to prepare the sand mold and cast the part, to compare the simulated result and experimental results, to reduce rejection rate and to enable the company to again start the production.

Design optimization of gating and feeding system through simulation technique for sand casting of wear plate

Machinability investigation of new material is one of the mandatory investigations to complete the purpose of creation of it. Electrical discharge machining (EDM) is one of the promising unconventional machining processes for highly accurate machining performance in difficult-to-cut material even machining complicated profiles. The powder-mixed EDM and nanopowder-mixed EDM are the improved versions of the EDM. The Al–Zn–Mg composite is reinforced with Si3N4 (9 wt. %) for meeting automotive and marine applications. The aluminium nanoparticles enhanced deionised water was used in NPMEDM. The nickel-coated brass and uncoated brass tube electrode were considered for the investigation. Pulse on time (µs), voltage (V), input current (A), and capacitance (nF) were independent variables and varied at 3 levels. The microhole machining performance with a coated and uncoated electrode was investigated. The L18 orthogonal array involved in the experimental design, material removal rate, and electrode wear rate were analysed. The SEM analysis was employed in the surface morphological study of electrodes before and after machining. The input parameters were optimised for the coated electrode for the responses of MRR and EWR.

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Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite

Casting simulation softwares are increasingly being used in modern foundries and metal casting industries. Softwares simulate the casting process in a virtual domain and provide insight into mold f...

Simulation tools in enhancing metal casting productivity and quality: A review:

The purpose of this paper is to study the relationship between inventory performance, both total inventory (INV) and its discrete components (raw material (RMI), work-in-process (WIP), and finished goods (FGI)), and financial performance in manufacturing companies

On the relationship between inventory and financial performance in manufacturing companies

Investigation of porosity in Al casting

Design Optimization of Feeding System and Solidification Simulation for Cast Iron

Lean six sigma feasibility and implementation aspect in cast iron foundry

IoT feasibility aspects of mold temperature monitoring and casting simulation for smart foundry

Numerical investigation of composite patch repair of inclined cracked panel using XFEM

The correct selection of production condition is one of the most important aspect to take into consideration in process related to electrical chemical machining (ECM) of conductive materials, as these condition determine important factors which affect on output. The material removal rate (MRR), roughness and over-cut were studied. Three parameters were changed during the experiments which are : feedrate of the electrode, electrolyte flow rate and voltage. Analysis of Variance has been carried out to identify the significant effect of input parameters on output. Authors have tried to develop predictive mathematical model of ECM process parameters (electrolyte flow rate, electrode feed rate and voltage's effect) in relation with process output (MRR, surface finish and overcut) by using secondary data(7). These predictive models can be used for optimization of output parameters and development of expert system. Keywords-ECM, Surface Roughness, MRR, Mathematical model, ANOVA.

R.S. Barot

Papers

Design Optimization of Feeding System and Solidification Simulation for Cast Iron

Lean six sigma feasibility and implementation aspect in cast iron foundry

IoT feasibility aspects of mold temperature monitoring and casting simulation for smart foundry

Numerical investigation of composite patch repair of inclined cracked panel using XFEM

Development of Predictive Mathematical model of process parameters in Electro Chemical Machining Process