Abstract: Centrifugal-casting machine is used in manufacturing
special machine components like multi-layer journal bearing used in
all internal combustion engine, steam, gas turbine and air craft turboengine
where isotropic properties and high precisions are desired.
Moreover, this machine can be used in manufacturing thin wall hightech
machine components like cylinder liners and piston rings of IC
engine and other machine parts like sleeves, and bushes. Heavy-duty
machine component like railway wheel can also be prepared by
centrifugal casting. A lot of technological developments are required
in casting process for production of good casted machine body and
machine parts. Usually defects like blowholes, surface roughness,
chilled surface etc. are found in sand casted machine parts. But these
can be removed by centrifugal casting machine using rotating
metallic die. Moreover, die rotation, its temperature control, and good
pouring practice can contribute to the quality of casting because of
the fact that the soundness of a casting in large part depends upon
how the metal enters into the mold or dies and solidifies. Poor
pouring practice leads to variety of casting defects such as
temperature loss, low quality casting, excessive turbulence, over
pouring etc. Besides these, handling of molten metal is very
unsecured and dangerous for the workers. In order to get rid of all
these problems, the need of an automatic pouring device arises. In
this research work, a robot assisted pouring device and a centrifugal
casting machine are designed, developed constructed and tested
experimentally which are found to work satisfactorily. The robot
assisted pouring device is further modified and developed for using it
in actual metal casting process. Lot of settings and tests are required
to control the system and ultimately it can be used in automation of
centrifugal casting machine to produce high-tech machine parts with
desired precision.
Abstract: The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.
Abstract: Among the chemicals used for ammunition production, TNT (Trinitrotoluene) play a significant role since World War I and II. Various types of military weapon utilize TNT in casting process. However, the TNT casting process for warhead is difficult to control the cooling rate of the liquid TNT. This problem occurs because the casting process lacks the equipment to detect the temperature during the casting procedure This study presents the temperature detected by infrared camera to illustrate the cooling rate and cooling zone of curing, and demonstrates the optimization of TNT condition to reduce the risk of air gap occurred in the warhead which can result in the destruction afterward. Premature initiation of explosive-filled projectiles in response to set-back forces during gunfiring cause by casting defects. Finally the study can help improving the process of the TNT casting. The operators can control the curing of TNT inside the case by rising up the heating rod at the proper time. Consequently this can reduce tremendous time of rework if the air gaps occur and increase strength to lower elastic modulus. Therefore, it can be clearly concluded that the use of Infrared Cameras in this process is another method to improve the casting procedure.
Abstract: Significant changes in oil and gas drilling have
emphasized the need to verify the integrity and reliability of drill
stem components. Defects are inevitable in cast components,
regardless of application; but if these defects go undetected, any
severe defect could cause down-hole failure.
One such defect is shrinkage porosity. Castings with lower level
shrinkage porosity (CB levels 1 and 2) have scattered pores and do
not occupy large volumes; so pressure testing and helium leak testing
(HLT) are sufficient for qualifying the castings. However, castings
with shrinkage porosity of CB level 3 and higher, behave erratically
under pressure testing and HLT making these techniques insufficient
for evaluating the castings- integrity.
This paper presents a case study to highlight how the radiography
technique is much more effective than pressure testing and HLT.
Abstract: This paper proposes the numerical simulation of the
investment casting of gold jewelry. It aims to study the behavior of
fluid flow during mould filling and solidification and to optimize the
process parameters, which lead to predict and control casting defects
such as gas porosity and shrinkage porosity. A finite difference
method, computer simulation software FLOW-3D was used to
simulate the jewelry casting process. The simplified model was
designed for both numerical simulation and real casting production.
A set of sensor acquisitions were allocated on the different positions
of the wax tree of the model to detect filling times, while a set of
thermocouples were allocated to detect the temperature during
casting and cooling. Those detected data were applied to validate the
results of the numerical simulation to the results of the real casting.
The resulting comparisons signify that the numerical simulation can
be used as an effective tool in investment-casting-process
optimization and casting-defect prediction.