International Journal of Innovative and Emerging Research in Engineering

Volume 4, Issue 1, 2017

Available online at www.ijiere.com
International Journal of Innovative and Emerging
Research in Engineering
e-ISSN: 2394 - 3343 p-ISSN: 2394 - 5494

Study of Modeling and Finite Element Analysis for a Die

Casting Component : A Review
BELSARE S.U.1a, BHOSALE A.B.2a, BOGAM R.R.3a, DEOKATE M.V.4a PROF.ADEWAR S.S.5b
a
B.E. Mechanical Engineering Department, ZCOER, Pune, Maharashatra, India
b
Prof. Mechanical Engineering Department, ZCOER, Pune, Maharashatra, India
a
belsareshreyas26@gmail.com
b
shraddha.adewar@zealeducation.com
ABSTRACT:
In present paper, a review for finite element analysis and finding out defects on die casting component. There
are some defects may present in the casting component because of incorrect design of gating, mould fill time
calculation, design of riser, Design of filler and much more parameters. Due to which it may create disturbance
while in their operation of the component. So that this review is taken to get survey on different optimization
techniques and design procedures to minimize the defects in the casting components.
Keywords: FEM, Die casting, Casting Defects, Casting Process Design, Casting analysis

I. INTRODUCTION
The internal threads in the elbow difficult to design, manufacture and operation. In the casting process for an elbow,
the prediction of shrinkage defect is a one of the important issue and failure of such component is a commonly
encountered problem. The non-uniform heat transfer rate is the main cause of such failure. The main defects in an elbow
are due to blowhole, shrinkage, lamination defect, hot tears/cracks. [5]
Metal casting process begins by creating a mold, which is the reverse shape of the part which we needed. The mold
is made from a refractory material, for example, sand. The metal is heated in an oven until it melts, and the molten metal
is poured into the mould cavity. The liquid takes the shape of cavity, which is the shape of the part. It is cooled until it
solidifies. Finally, the solidified metal part is removed from the mould. [5][6]
There are following defects are observed during casting process : [3][7]
1) Shifts
2) Warpage
3) Fin
4) Swell
5) Blowholes
6) Drop
7) Dirt
8) Honeycombing or sponginess
9) Metal Penetration and rough surface
10) Sand holes
11) Pin holes
12) Scabs
13) Shrinkage cavity
14) Hot tears (Pulls)
15) Cold shut and mission
16) Poured sort
17) Internal air pocket

II. LITERATURE REVIEW

K. Chadhaa et al [1] investigated ingot forging process by using double hit hot compression tests and compared
temperature, strain rate, length and interpass time with respect to Total recrystallization fraction graphically and
experimentally by using avrami equation.
B. Thakre et al [2] presented the review on on the physical and numerical modeling of tundish. A number of studies have
been agreed in order to study the effect of various parameters and design of tundish in continuous flow casting process.

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 International Journal of Innovative and Emerging Research in Engineering
Volume 4, Issue 1, 2017
A. Juriani et al [3] were studied the different casting defects names, causes and Remedial measured briefly. By using
cause and defect analysis concept the various causes and remedial measures are suggested. This study will be highly
useful in reducing casting defects in industries and improving the quality of casting with minimized rejection.
B. Patel et al [4] were studied Casting solidification is actually the transformation of liquid phase to solid phase with the
liberation of latent heat of the fusion. During this metallurgical process, it induces casting defects like shrinkage, porosity
and hot tears. To eradicate and eliminate these problems, accurate casting design and proper design of gating system is
necessary.
V. Bijagare et al [5] were studied the casting process of aluminium component. During simulation it has been observed
that the heat dissipation rate depends on the ratio of surface area to the volume of the casting. It is also observed that the
higher ratio results in faster and proper directional solidification of fluid metals.
K. Pathak et al [6] were experimented on the simulation result obtained for aluminum alloys (Al-201). He was also
worked on solidification with respect to different sections like triangular, half hexagonal, circular, square. They are also
studied Shrinkage porosity, velocity and mould fill time under different sections.
R. Rajkolhe et al [7] were studied different casting defects. Also its causes and remedies is studied in detailed. By
referring different research papers causes and their remedies are listed. So that the industrial benefits while eliminating
casting process is the output of this work.
C. Choudhari et al [8] were investigated casting simulation using ANSYS has been carried out to obtain the isotherms at
various times. The results obtained from simulations and from real casting are in good agreement which show the
accuracy of model discretization in ANSYS environment.
K. Han et al [9] were studied the filling pattern and product defects, and verified them using the commercial software,
MAGMAsoft for the optimal design of the alternator housing. It is expected the effectiveness of a fixed quantity
connected directly with it, will increase, such as the reduction of defects, quality enhancement, and a productivity
increase due to this research results.
A. Oza et al [10] were review about finite element analysis and design of experiment method in the field of gravity die
casting They are concluded that there is wide applicability of finite element analysis and design of experiment method in
the field of gravity die casting which solves the difficulty of defected cast component and improves the quality of final
solidified cast component.
H. Liu et al [11] were analyzed Semi-Solid Die-Casting process of Magnesium Alloy hook. For which they had taken
experiment tests of rheological property of AZ91D alloy. Numerical simulation for the rheo-diecasting and filling
process is also carried out for better results. The value of the apparent viscosity compared with the solid-phase scores and
the shearing speed.
S. Shaha et al [12] were studied the heat flow of cold set resin bonded sand mould was simulated using JL Analyzer FEM
analysis software. The whole study divides into two parts; firstly, the prediction of heat flow through the mould wall and
secondly, through the casting of gray cast iron. They also studied Simulation of heat flow, Molding and casting, Heat
flow through the sand mould, Microstructure and various Hardness values of cast products.
N. Parinda et al [13] were studied and discussed the various non-destructive techniques used for inspection of castings.
Since it is not practically possible to extend the discussion to every details of all the techniques, the extents of the
discussion are kept to the minimum.
Dr. S. Shamasundar et al [14] were studied Advanced casting simulation tools like Procast allow the foundry engineer to
quickly bridge the gap between design and manufacturing. Optimization or improved efficiency during the
manufacturing cycle leads to substantial time and cost savings. Productivity, quality improvements are possible by
meticulous usage of simulation procedure.
III. CONCLUSIONS
We studied the different casting defects occurred during casting process. To reduce that defect different points
considered into the account. That are :-
Modification of foundry
Design and safety of casting
Risering of casing
Gating ratio
Type of casting
Material of casting to be selected
ACKNOWLEDGMENT
It is a advantage for us to have been associated with Prof. S.S.Adewar, Prof. in Mechanical Engineering Department,
ZCOER, pune during this paper work. I have been greatly benefited by her valuable suggestions and ideas and discussion
about this valuable work. It is with great pleasure that I express my deep sense of gratitude to him for his valuable
guidance and constant encouragement throughout this work.

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Volume 4, Issue 1, 2017
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