Analysis and minimization of sand- cast defects for casting aluminum A356 alloy through Pro CAST simulation
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Date
2024-06
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Abstract
In this research analysis of the existing casting process through scientific tools at the case company, Selam Children Village Tsehayi Roschili Industrial and Agricultural Engineering in Addis Ababa Ethiopia is conducted. Inside foundry shop of case company defect becomes the most series problem, which makes the product to reject due to certain quality and bad surface finish. From different products, pulley product are selected using failure mode analysis and further analysis is conducted on it. In this investigation, various casting process parameters such as mold initial temperature, molten metal flow rate, newly designed model with three different scenario and pouring temperature considered. Then simulation are conducted according to Taguchi L18 orthogonal array. 3D model for the product designed on solid work 2022 and imported to Pro-CAST software for simulation. Different real time parameters given as input and various simulation carried out. From meticulous simulation, it is achieved a remarkable 100 percent void-free casting process. This outcome ensures structural integrity and enhances the reliability of the final components. Hotspot occurrences also reduced from an initial 35 points to an impressive 14 points. This optimization mitigates localized stress concentrations and enhances overall part performance. On further investigation, total volumetric of shrinkage porosity is also successful decreased from 5.67% to 4.77%. This improvement has direct impact on material density and mechanical properties of products. Additionally total defect distance on the ISO surface of product was significantly minimized from 55.62 cm to 25.59 cm. Finally, from selected trial according to Taguchi method and grey relational analysis with Minitab 21.2 software 52.22% total defect minimization is achieved.
Depending on the simulation result, selected pulley part fabricated inside foundry shop from aluminum A356 metals. Comparison between previous fabricated products with ought casting simulation software and new product that made after simulation result done and result of sample tested under scanning electron microscope machine presented.
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Casting, Aluminum A356, Defect, Pro CAST, Simulation, Foundry