Effect of gating design on the quality of grey iron casting

Tema ovog diplomskog rada je ispitati utjecaj oblika uljevnog sustava na kvalitetu odljevka od sivog lijeva. U teoretskom dijelu diplomskog rada opisana je tehnologija lijevanja, svojstva, mikrostruktua i primjena sivog lijeva. Opisani su i pojašnjeni elementi uljevnog sustava i njihova funkcija, podjela i karakteristike. U eksperimentalnom dijelu ovog rada za zadani odljevak bilo je potrebno konstruirati kalup s dvanaest kalupnih šupljina i nekoliko varijanti CAD modela vertikalnog uljevnog sustava te promjenom konstrukcije, parametara i veličine elemenata ispitati utjecaj varijanti na zadani odljevak. Svaki model je bio ispitan u programu QuikCAST® ili ProCAST®, te su se analizirali dobiveni rezultati. Nakon konstrukcije uljevnog sustava, po konačnom modelu se vršila operacija lijevanja na DISAMATIC® automatskoj liniji u tvrtci Ferro-preis d.o.o. u Čakovcu. Na dobivenom odljevku napravljena je metalografska analiza i radiografsko ispitivanje na Fakultetu strojarstva i brodogradnje u Zagrebu. Metalografskom analizom utvrđena je mikrostruktura i tip listićavog grafita. Pomoću radiografskog ispitivanja utvrdilo se nastajanje usahline na odljevku.The topic of this thesis is to analyze the effect of the gating system on the quality of the casting made of grey iron. In the theoretical part of the thesis the casting methods, properties, microstructures and the application of the grey iron were made. The elements of the gating system and their function, characteristics and configuration were explained In the experimental part of the thesis, the task was to design the mold with twelve cavities and to design several variations of CAD models of vertical gating system for the given casting. The changes made to the gating system such as design methods, parameter optimization and element size were analyzed for the given casting. Each CAD model was analyzed in QuikCAST® or ProCAST® software package, and the results were discussed. After the final CAD model was designed, the die casting operation was made on DISAMATIC® assembly line in Ferro-Preis company in Čakovec. The metalographic and radiographic analysis was made on the casting on Faculty of Mechanical Engineering and Naval Architecture in Zagreb to determine casting defects and microstructure