Defect Analysis and Process Parameter Optimisation in Sand Casting

M/s. Boparai Metals, a small scale industry situated in Industrial Area, Mohali, Punjab is manufacturing and supplying automotive and non automotive component to tractor companies in Punjab and aiming to provide the best solutions. The company is facing the problem of castings defects i.e. porosity, hot spot and shrinkage in cooler plate during the Sand Casting process. In this work, the study of existing process was done to find the root cause of the problem. Three dimensional gating system of cooler cover plate were modified by using UG– NX software. The models were imported using ADSTEFAN software for simulation of SAND-CASTING process. Based on the specification of cooler cover plate material, cast iron moulds in the green sands and input process parameters; design calculation of casting model was undertaken. Three case studies i.e. analysis based on the solidification method, were carried out for defect analysis of casting component and simulation study was done for process parameter optimization using ADSTEFAN software. It was observed that molten metal enters at critical location of cover plate causing turbulence in metal flow and solidification was not getting achieved in the directional way, thereby resulting in shrinkage defect. The shrinkage defect was removed by providing risers at proper location