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Design and Analysis of Cylinder Liner Die to Reduce

Centrifugal Casting Defects
Saad Mohamood

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1/29/2020 (PDF) Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects | Saad Mohamood - Academia.edu
 

Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects  D O W N LO A D

 
Design and Analysis of Cylinder Liner Die to Reduce Centrifugal

Casting Defects
*  ** 
 Anurag Vaijanath Kulkarni  , Santosh Patil   
Abstract
Cylinder liners are one of the crucial components whose part quality affects
engine performance of automobile. Cylinder liners guides piston to
reciprocate during combustion process. Cylinder liners are manufactured by
centrifugal casting process. Centrifugal casting process operates through

process parameters
temperature of molten such
metal,as preheating
surface temperature
temperature of die,
of die during pouring
solidification
process, convective heat transfer & rotational speed of die. Improper
combination of process parameters leads to generation of casting defects such
as segregation, shrinkage porosity etc. The use of defective Cylinder liners in
engines leads to catastrophic failure of part while machining because of low
strength. Hence, it is necessary to carry out FEA (Finite Element Analysis) of
cylinder liners to minimize centrifugal casting defects such as shrinkage
porosity, segregation& improve part quality. This article explains transient
thermal analysis of cylinder die which is carried out with ANSYS Workbench
software. Maximum heat flux rate during the solidification process is used as
crucial parameters to find the influence of process parameters on
solidification rate and centrifugal casting defects.

 Keywords:  Cylinder liner, centrifugal casting, centrifugal casting defects,

Thermal Analysis.

Introduction solidification process i.e. steady state solidification

or rapid solidification. In steady state
Centrifugal casting process
Eckhardt. Centrifugal was invented
casting by A.G
uses centrifugal
force to solidify molten metal inside rotating
mold. Centrifugal casting process is classified into
three types depending upon orientation of spinning
1
axis i.e. vertical, horizontal & inclined.   maximum heat flux rate during the process. Heat
Centrifugal process operates through process
 parameters such as preheating temperature of
mold, pouring temperature of molten metal,
surface temperature of mold during solidification
& rotational speed of mold, pouring rate etc.
Centrifugal casting is a transient heat flow process
in which inside diameter of die is subjected to  
thermal loads. The process is used to produce
hollow cylindrical parts with comparatively more
reliability than the parts produced by static casting
 process. The Gravitational factor i.e. G factor  
 plays important role in designing of centrifugal
casting process. G factor is defined as ratio of
centrifugal force developed during process to
gravitational force. The range of G factor varies as
1,2
 per selection of material.  Improper combination
of process parameters affects nature of
https://www.academia.edu/33747895/Design_and_Analysis_of_Cylinder_Liner_Die_to_Reduce_Centrifugal_Casting_Defects
solidification, the heat flow during the
solidification process remains constant whereas in
other case the rate of heat transfer during
solidification process is variable. The nature of
solidification process can be studied with help of
flux during the process represents the maximum
heat transferred to surrounding per unit area
through convection in current case. Heat flux rate
during the solidification process can be stated as
the function of preheating temperature, Pouring
temperature as well as cooling temperature and
pressure. The cooling rate influences
microstructure, casting hardness, circumferential
and axial cracks, machine productivity as well as
life of cylinder die. Uniformly solidified castings
produce fine grained microstructure whereas
rapidly and comparatively slowly solidified
castings shows coarse grained microstructure
which involves the risk of forming centrifugal
casting defects. Thus, the unstable cooling rates of
cylinder die causes casting defects such as
2/13
1/29/2020 (PDF) Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects | Saad Mohamood - Academia.edu
p p
*
Student M. Tech. (CAD/CAM/CAE), Department of Mechanical Engineering, Rajarambapu Institute of Technology,
Rajaramnagar, Sangli, Maharashtra, India
Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects
**
Professor, Department of Mechanical Engineering, Rajarambapu Institute of Technology, Rajaramnagar, Sangli,  D O W N LO A D
Maharashtra, Indiato:  Mr. Anurag Vaijanath Kulkarni,   Department of Mechanical Engineering, Rajarambapu Institute of
Correspondence
Technology, Rajaramnagar, Sangli, Maharashtra, India. E-mail Id: kanurag71@gmail.com

© ADR Journals 5. All Rights Reserved. 

Kulkarni AV et al. 

segregation,
lowers shrinkage,
quality porosity liner
of cylinder & Raining which
& causes Material allowable
ultimate selected for die isis 460Mpa.
stress structuralBy
steel &
using
catastrophic failure during operating conditions. torsional stress equations we have,
These casting defects can be minimized by
optimizing process
2
parameters. Thus, the σ = [×
 ]/
  (5)
optimization of process parameters in centrifugal
casting process will i mprove solidification process Where, σ, T, R and r are the allowable stress,
and quality of parts in terms of mechanical torque, outer radius and inner radius of die
strength will be improved. respectively.

Design of Cylinder Die We have r=230mm, T= 10.45E6 N.m and

σ=460Mpa. Therefore by substituting the values in
Structural steel is selected to manufacture equation no.(5)we get, R=289mm.
cylindrical die. The cylindrical die is designed for
minimum possible diameter. The cylinder liner ID The length of cylinder liner is 1200mm. Now
is 460mm.Let us assume that cylinder liner finding minimum angular deflection to design
minimum OD is equivalent to cylindrical die length of die is done by using Shear Modulus
minimum ID with uniform thickness applied over Equation
the length of cylindrical die. Now,
  σ = ×∅×

  (6)
G Value =  
  (1) Where, G, L and Ø represents shear modulus,
length of cylinder liner and st atic angular
deflection of shaft driving power to flange of die.
G Value = ∗∗∗
∗
  (2)  Now, rearranging equation no.(6) we get

×
Where 'W' is the rotational velocity of cylindrical ∅ =  
×
die.terms
in Therefore Rotational
of revolutions per speed
minuteofcan
cylindrical die
be given by Substituting the values we get,

Ø1= 0.05 radians.

N = .×  G/D (3)
Length of cylinder die should be greater than
Length of cylinder liner. Static deflection is
Where D is minimum Outer diameter of die. directly proportional to Length & keeping
tolerance of +0.002radians i.e. Using Ø2 =
The material selected to manufacture cylinder
0.07radians
liner is cast Iron & G factor ranges from (75-100)
for cast iron. Hence, finding minimum required σ×L
rotational speed of mold as per G value. Taking ∅ =  
29 ×
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1/29/2020 (PDF) Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects | Saad Mohamood - Academia.edu
G=75 we get N= 540Rpm.2,9  
×
∅×G×r
 power available = 6Kw L=  
σ
Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects
×
 D O W N LO A D
Torque = 
  (4) Substituting the values in above equation we get,

The length of cylindrical die (L) = 1314mm. 

Substituting the values we get,
Torque =10.45E6 N.m

 J. Adv. Res. Auto. Tech. Transp. Sys. 5; : - 9.

  Kulkarni AV et al.

Cad Model and Geometrical Detail of Cylinder Die 

Figure 1.CAD Model of cylinder die

S. No. Part Name Dimensional Value
1) The Inner diameter of cylindrical die 460 mm
2) The Minimum Outer diameter of cylindrical die 578 mm
3) The Maximum Outer diameter of cylindrical die 780 mm
4) The Length of cylindrical die 1314 mm
5) The taper angle provided over length 9°

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1/29/2020 (PDF) Design and Analysis of Cylinder Liner Die to Reduce Centrifugal Casting Defects | Saad Mohamood - Academia.edu
Table 1.Geometrical Details of die
In Use Process Parameters  process parameters of centrifugal casting process
Design and Analysis of Cylinder Liner
The table shown belowDie to the
represents Reduce
current Centrifugal Casting Defects
which gives birth to casting defects
shrinkage, hot tears etc.
such as  D O W N LO A D

S. No. Name Of the process parameter Value of process parameter

1) Preheating Temperature 300°C
2) Pouring Temperature 1400°C

3)
4) Surface Temperature
Rotational of die
Speed of die 100°C-150°C
540Rpm
Table 2.In Use Process Parameters of centrifugal casting

Experiments and Test conducted ∆T2=Pouring Temperature-Surface Temperature of die

The Centrifugal casting is convection heat transfer
 process. The total heat generated in the cylinder
die is transferred through convection. The total
amount of heat generated due to pouring of molten
metal as process begins is calculated as follows
and the Process variables involved are described in
table 2.
Heat generated during the pouring conditions (H1)
H1=M×Cp×∆T1 (7)
where,
∆T1= Pouring Temperature-Preheating Temperature
Heat transferred through convection during
solidification process (H2)
H2=h×A×∆T2 (8)
Equating equations no.(7) and (8), and substituting
values we get, h=275W/m2.k.
Transient Thermal Analysis
The word 'Transient' indicates that heat flow in the
 process is function of time i.e. heat flux at the
 beginning and at the end of solidification process
is different. In Centrifugal casting the cylindrical
die is preheated before pouring molten metal so as
to avoid damages due to thermal loads. The
 process of Pouring molten is followed by
 preheating of die. As soon as metal is poured
inside the die, cooling nozzles are turned ON and
solidification process starts. The cooling of
centrifugal die transforms molten metal into solid
 part. To know flow of heat transfer throughout
solidification process in terms of heat flux
converged it is essential to carry out transient

 J. Adv. Res. Auto. Tech. Transp. Sys. 5; : - 9.

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