Optimisation of the Gating System Components Using 3D CAD Modelling and Casting Simulation to Improve the Casting Yield

摘要

Foundries are primary suppliers to the manufacturing industries like automobile, pumps, transport, heavy equipment, machine tools, plant machinery, machines, households, aerospace, defence. Although lots of research have been carried out in foundry technology, yet achieving higher casting yield with the sound casting (defect-free casting) is major challenge to the manufacturers. For obtaining high quality of casting which is prime requirement of customers, manufacturers are making compromise with the casting yield which results into the increase in production cost and decrease in profit. In the research, brake disc casting is studied and analysed to overcome the problem of lower casting yield. Lower casting yield results from improperly designed gating system and risers. For improving the yield, the gating system components such as sprue, sprue well, ingates and risers are redesigned using the feeding rules, gating design procedure, theoretical knowledge, practical considerations and casting simulation results. The various designs of the gating system components are made and 3D CAD model of each design is made and analysed using casting simulation software AutoCAST-X Flow Plus. After analysing the simulation results, if required goal is not achieved, then the respective changes are made in design and 3D CAD model and it is again simulated. The procedure is repeated until the required results are obtained. Finally, redesigned gating system and risers are used to achieve higher casting yield and as yield increases, productivity and profit increases.