Methoding and Simulation of LM 6 Sand Casting for Defect Minimization with its Experimental Validation

AbstractThe solidification of metals continues to be a phenomenon of great interest to physicists, metallurgists, casting engineers and software developers. It directly affects the production cycle time, internal quality of castings and material utilization (yield). The process of casting solidification is complex in nature and the simulation of such process is required in industry before it is actually undertaken. The volumetric contraction accompanying solidification of molten metal manifests in defects like shrinkage cavity, porosity, and sink. These defects can be minimized by an intelligent methoding and simulation using casting software. In this paper, an attempt has been made to redesign and develop a casting free from defects, in particular, shrinkage defect. The component taken for methoding and simulation study was subjected to high amount of shrinkage defects which was the major cause for the rejection in the foundry. It also was having very low yield as 45% as per the foundry information. The component under study consists of square shaped (at top) plate having three perforations with diminishing height (at bottom) and subjected to multiple hot spot. Therefore, optimum location of feeder has been identified by carrying out various simulation trials. Proper feeding aids have helped in getting the hot spot completely shifted inside the feeder. Simulation based approach has helped in the improvement of the feedability index which represents yield of feeders and quality of casting (percentage of volume free from shrinkage porosity). The simulations results were compared with the experimental trial and the comparison was found to be in good agreement