CastingDesignandSimulation 2012

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

Metal ProductionFoundry JobbingFoundry

CastIron 2 5% 4 8%
CastingDefects Steel 5 10% 8 15%
Aluminum 10 15% 10 20%

CastingRejections
QualityConformance
DefectClassification
DefectCharacterization

EFoundry,I.I.T.Bombay IRON STEEL ALUMINUM

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

Shrinkage By Appearance Criticality DiscoveryStage

GasPorosity Projections Small/Minor/ Casting (Foundry)
BlowHole Reparable RoughMachining
Cavities
ColdShut FinishMachining
Discontinuities Large/Major/
Misrun/Unfill Irreparable ProductService
SandInclusion PoorSurface
SlagInclusion Incomplete Part
High
HotTear/Crack IncorrectShape
MANAGEABLE DANGER
Criticality

Distortion/Warp Inclusions
Scabbing
ExcessFlash DefectivePPM By Location IDEAL PROBLEM
OtherDefects (partspermillion) External Low
0 20000 40000 60000 80000 100000 Internal Early DiscoveryStage Late

CastingDefects Prof.B.Ravi,I.I.T.Bombay CastingDefects:CavityCreation Prof.B.Ravi,I.I.T.Bombay

ConformanceCriteria ImproperClosure
Geometry Integrity Property Acrosspartingplane:
flash
Tooling Material
Alongpartingline:
CavityCreation Melt,Pouring Solidification mismatch
FLASH
Dimensions Flash Unfilling Shrinkage Segregation
Shape Mismatch Blowhole Hottear Hardspots
Features Scab Gasporosity Distortion Strength
Inclusions Swell
MISMATCH

[AtlasofCastingDefects,
InstituteofBritishFoundrymen]

(c)B.Ravi,IITBombay 1
CastingDesignandSimulation 2012

CastingDefects:CavityFilling Prof.B.Ravi,I.I.T.Bombay CastingDefects:SolidificationShrinkage Prof.B.Ravi,I.I.T.Bombay

IncompleteFilling: coldshut,misrun Internal:Cavity,porosity,centreline,pipe

SolidInclusions:sandinclusion,slaginclusion External:Cornershrinkage,sink SINK
GaseousEntrapments:blowhole,gasporosity
PIPE

POROSITY
CORNER
[AtlasofCastingDefects,
COLDSHUT MISRUN INCLUSION BLOWHOLE GASPOROSITY InstituteofBritishFoundrymen]
SHRINKAGE

CastingDefects:CoolingStresses Prof.B.Ravi,I.I.T.Bombay DefectCharacterization Mismatch Prof.B.Ravi,I.I.T.Bombay

TYPE Integrity
HinderedCoolingContraction: Hottear,coldcrack,
Appearance Shapeirregularity
distortion,swell DefectSize Medium tolarge
Location External, surface
Consistency Samelocation (parting)
Discoveryat shakeout
Inspection Visual
Metacause Root cause
Incorrect patternplates Manufacturingmisalignment
Improper molding Mold rammingandclosure
Moldmisalignment Moldpinsdeformed

HOTTEAR DISTORTION SWELL

DefectCharacterization ShrinkagePorosity Prof.B.Ravi,I.I.T.Bombay DefectCharacterization GasPorosity Prof.B.Ravi,I.I.T.Bombay

TYPE Integrity TYPE Integrity

Appearance Roughlocalizedcavity Appearance Smoothsphericalcavity
DefectSize Smalltomedium DefectSize Small
Location Internal,hotspot Location Internal,hotspot
Consistency Nearthick sections Consistency Differentlocations
Discoveryat Machining Discoveryat Machining
Inspection Radiography Inspection Radiography
Metacause Root cause Metacause Root cause
Incorrectfeeder design Small size(lowmodulus) Typeofmetal/alloy Metal/alloycomposition
Thinconnection(neck) Affinity andexposuretogassource
Insufficientquantityofmetal Largevolumetricshrinkageofmetal Gas entrapment Degree ofsuperheat
Lowcapacityof feeder(usefeedaids) Inadequatedegassingtreatments
Feedingdistance Feedertoofarfromhotspot High coolingrate Moldmaterial, moldwallthickness

(c)B.Ravi,IITBombay 2
CastingDesignandSimulation 2012

DefectCharacterization BlowHoles Prof.B.Ravi,I.I.T.Bombay DefectCharacterization HotTearorCrack Prof.B.Ravi,I.I.T.Bombay

TYPE Integrity TYPE Integrity

Appearance IrregularSmoothcavity Appearance Visiblefracture
DefectSize SmalltoMedium DefectSize SmalltoMedium
Location Internal, NeartoTop Location External, surface
Consistency Slightlyvarying Consistency Varyingsize,shape
Discoveryat RoughMachining Discoveryat Shakeout,cooling
Inspection Radiography Inspection Visual
Metacause Root cause Metacause Root cause
Airandgasentrapment Fastpouringrate Variable coolingrate Sharpcornerinpart
Poordegassingofmoltenmetal Suddenchangeinthickness
Combustionofmold binder Mold/core characteristics Highhardnessofmold/core
Mold ventingpoor Finesand,excessbinder,hardramming Impropershakeout Highvibration rate
Inadequateventingchannels Hightemperature atshakeout

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

Metalcastinginvolveshighlevelofrejections(percent) Connectdefectswithcommonmetacausesandrootcauses:

duetolargenumberofvariablesandinterrelationship
Rejectionsrepresentlossofmaterial,energy,productivity Defect Metacause Rootcause
Longtermimpactonemployeemoraleandcustomerbase
Distortion Highstresses Rigidmold
Castingdefectsrelatedtogeometry,integrity,properties
Shrinkage Hightemperature Highpouring
Causedduringmold making,metalfilling,solidification
Porosity gradients temperature
Characterization:identification,metacauses,rootcauses
HotTear Lowtemperature Rapidcooling
gradients

(c)B.Ravi,IITBombay 3