Modelling, Simulation and Process Development of Sand Casting Process

The various parts of automobile products are made by using the casting process as it is economical and can produce complex geometry. SOLIDCast is a very powerful tool to visualize mold filling, solidification, and cooling and to predict the location of internal defects. The foundry industry suffers from poor quality and productivity due to a large number of process parameters. Casting simulation can save the material and number of foundry resources involved in a foundry trial. A large number of foundries use the trial and error method in casting production, which affects the productivity of a company. In todays competitive age of foundries are required to more active and efficient. The objective of the study is to design the methoding system and optimize it. This project aims to study the existing method for qualitative prediction method and develop some empirical model which will provide a quantitative prediction of defects using casting simulation software for ductile iron casting considering geometric and thermal parameters. Prediction of the size and location of shrinkage defect by considering geometric and thermal parameters during solidification in a casting.