Casting Simulation Report

Customer : Helios Syscom Pvt. Ltd

Project : Dipper Cavity
Results : Flow & Solidification Analysis
New Method Development

Document Type : Controlled Circulation

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Method Details – M1_A

Process : Sand Casting

Alloy : BS-3100 A4
Mold : Silica Sand
Mold Temp : 100 °C
Pouring Temp : 1600 °C
Pouring Time : 25 sec
Weight : 64.13 kgs
Yield : 55.85 %

Sleeve Details : 2.5’ x 4’

Flow Simulation Results - Temperature

Fluid flow with respect to temperature

Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Flow Simulation Results - Temperature
Solidification Results- Temp

Solid Analysis - 5% Solid Analysis - 20% Solid Analysis - 40%

Solid Analysis - 60% Solid Analysis - 80% Solid Analysis - 100%

Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State

Break in liquid state, which will result in shrinkage

Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Liquid State
Solidification Results- Shrinkage

Shrinkage is observed in the Casting

Solidification Results- Shrinkage

Shrinkage is observed in the Casting

Inferences

From slide no. 4 to 28 shows the Dipper Cast Model existing method simulation results
a) Slide no. 4-14 shows temp flow results
b) Slide no. 15 shows temp solidification results
c) Slide no. 16-27 shows liquid state solidification results
d) Slide no. 28-29 shows the shrinkage results

Overall conclusion: Method is NOT OK

Contact Details

Contact us for Software and Services

Z-Cast PRO – Casting Simulation Software

Flow, Solidification & Defect prediction Process to the Shop floor accuracy

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General Manager – Sales & Services
ganesh@dhioresearch.com
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