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

© ADR Journals 2015. All Rights Reserved.

Kulkarni AV et al.
segregation, shrinkage, porosity & Raining which
lowers quality of cylinder liner & causes
catastrophic failure during operating conditions.
These casting defects can be minimized by
optimizing process parameters.2 Thus, the
optimization of process parameters in centrifugal
casting process will improve solidification process
and quality of parts in terms of mechanical
strength will be improved.
Design of Cylinder Die
Structural steel is selected to manufacture
cylindrical die. The cylindrical die is designed for
minimum possible diameter. The cylinder liner ID
is 460mm.Let us assume that cylinder liner
minimum OD is equivalent to cylindrical die
minimum ID with uniform thickness applied over
the length of cylindrical die. Now,
G Value = (1)
∗ ∗ ∗
G Value = ∗
(2)
Where 'W' is the rotational velocity of cylindrical
die. Therefore Rotational speed of cylindrical die
in terms of revolutions per minute can be given by
N = 42.3 × G/D (3)
Where D is minimum Outer diameter of die.
The material selected to manufacture cylinder
liner is cast Iron & G factor ranges from (75-100)
for cast iron. Hence, finding minimum required
rotational speed of mold as per G value. Taking
G=75 we get N= 540Rpm.2,9
power available = 6Kw
×
Torque = (4)
Substituting the values we get,
Torque =10.45E6 N.m
2
Material selected for die is structural steel &
ultimate allowable stress is 460Mpa. By using
torsional stress equations we have,
×
σ=[ (5)
( )]/
Where, σ, T, R and r are the allowable stress,
torque, outer radius and inner radius of die
respectively.
We have r=230mm, T= 10.45E6 N.m and
σ=460Mpa. Therefore by substituting the values in
equation no.(5)we get, R=289mm.
The length of cylinder liner is 1200mm. Now
finding minimum angular deflection to design
length of die is done by using Shear Modulus
Equation
×∅×
σ= (6)
Where, G, L and Ø represents shear modulus,
length of cylinder liner and static angular
deflection of shaft driving power to flange of die.
Now, rearranging equation no.(6) we get
×
∅1 =
×
Substituting the values we get,
Ø1= 0.05 radians.
Length of cylinder die should be greater than
Length of cylinder liner. Static deflection is
directly proportional to Length & keeping
tolerance of +0.002radians i.e. Using Ø2 =
0.07radians
σ×L
∅2 =
×
∅2 × G × r
L=
σ
Substituting the values in above equation we get,
The length of cylindrical die (L) = 1314mm.
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3 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°
Table 1.Geometrical Details of die

In Use Process Parameters process parameters of centrifugal casting process

which gives birth to casting defects such as
The table shown below represents the current shrinkage, hot tears etc.

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

1) Preheating Temperature 300°C
2) Pouring Temperature 1400°C
3) Surface Temperature of die 100°C-150°C
4) Rotational Speed of die 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

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Kulkarni AV et al. 4

thermal analysis of centrifugal casting process 3) Surface temperature of die during

with process parameters such as preheating solidification=100°C
temperature, pouring temperature & Surface
temperature of die during solidification. 4) Convection heat transfer coefficient =
275W/m2.k
Meshing Details
A set of preheating temperatures is used in the
1) Number of nodes: 6601 analysis keeping pouring temperature constant.
Similarly a set of pouring temperature is created
2) Number of elements: 3344
keeping preheating temperature constant.
3) Element size: 1 Maximum heat flux rate is found out in both the
cases & higher heat flux rate promoting
4) Level of refinement: 2
parameters are selected to channelize uniform
Boundary Conditions: The boundary conditions solidification of casting.8
applied for transient thermal analysis of
cylindrical die are as follows: Material: Grey Cast iron is selected to
manufacture cylinder liners by centrifugal casting
1) Pre heating temperature of cylindrical process. The material Properties entered for
die=300°C thermal analysis of cylinder liner are as follows:

2) Pouring temperature = 1400°C

S. No. Name of Mechanical Property Values

1) Density 7200 kg/m3
2) Thermal Conductivity 83 W/mk
3) Specific heat 500J
4) Thermal coefficient of expansion 12e-6/k
Table 3.Mechanical Properties of Material

Results and Discussion through analysis of current process parameters.

Following table represents relationship between
The time required for solidification of cylinder preheating temperature with heat flux rate when
liner is 40min.Maximum heat flux was calculated pouring temperature is kept constant.
S. No. Preheating Pouring Temperature Maximum heat Minimum heat flux
Temperature flux rate (W/mm2) rate (W/mm2)

1) 300 1400 35.350 0.03737

2) 290 1400 35.652 0.04357
3) 280 1400 35.971 0.03578
4) 270 1400 36.292 0.03178
Table 4.Preheating Temperature vs Maximum Heat Flux Rate

Therefore, from above data 270°C is selected as relationship between pouring temperature &
preheating temperature due to maximum heat flux maximum heat flux rate when preheating
rate. Similarly, following table shows the temperature is kept constant i.e. 270°C.
S. No. Preheating Pouring Temperature Maximum Heat Minimum Heat
Temperature flux rate flux rate
1) 270 1400 36.292 0.03178
2) 270 1350 34.686 0.03269
3) 270 1300 33.052 0.03575
4) 270 1250 31.475 0.02323
Table 5.Pouring Temperature vs Maximum Heat Flux Rate

The fluidity of molten metal is more at higher 1300°C is selected as pouring temperature due to
temperature. Selecting higher pouring temperature maximum heat flux rate available during
also increases solidification time. Therefore, solidification process.

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5 Kulkarni AV et al.

Figure 2.Preheating Temperature vs Maximum Figure 3.Pouring Temperature vs Maximum

Heat Flux Heat Flux
S. No. Preheating Pouring Maximum Maximum Change in
Temperature (°C) Temperature (°C) Heat Flux at Heat Flux at Heat Flux
T=1sec T=2500sec (W/mm2)
2 2
(W/mm ) (W/mm )
1) 300 1400 35.31 35.65 0.34
2) 270 1300 33.06 33.08 0.02
Table 6.Comparison of Process Parameters with Analysis Results I

FEA Analysis of In Use Process Parameters

The figures below represent total heat flux rate of (T=1sec) & at end of solidification process
cylinder liner at current process parameters during (T=2500sec).
centrifugal casting process at very initial time

Figure 4.Total heat flux at T=1sec Figure 5.Total heat flux at T=2500sec

FEA Analysis of Optimized Process Cylinder liner at Analyzed process parameters

Parameters during centrifugal casting process at very initial
time (T=1sec) & at end of solidification process
The figure below represents total heat flux rate of (T=2500sec).

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Kulkarni AV et al.
Figure 6.Total heat flux at T=1sec
In the analysis of current process parameters it is
observed that maximum heat flux is increasing
with time as the solidification process progresses.
But, Maximum heat flux should decrease with
time as temperature gradient should decline with
solidification due to lowering of surface
temperature. If heat flux increases with
solidification time which means the time required
for solidification also increases. This indicates that
surface temperature of die does not decrease
linearly with time. In another case where
maximum heat flux is constant as solidification
process progresses i.e. surface temperature of die
decreases linearly with time which interprets that
uniform solidification of die occurs. Thus,
Uniform solidification of die results in defects free
cylinder liner.
Thermal Structural Coupled Analysis
Centrifugal casting is a process of solidifying
molten metal poured in rotating die to form the
casting of desired size and shape. The molten
metal poured in the centrifugal die produces large
quantity of heat. The heat generated inside the die
applies thermal load on the inner surfaces of die
and flange supporting disc which restricts flow of
molten metal in the die during the pouring
conditions. Thermal loads induced in the rotating
domain of centrifugal casting process generate
thermal stress in castings due to structural
S. No. Preheating Temperature (°C) Pouring Temperature (°C)
1) 300 1400
2) 290 1400
3) 280 1400
4) 270 1400
Table 7.Preheating Temperature vs Equivalent Stresses
6
Figure 7.Total heat flux at T=2500sec
constraints involved in the process. The Thermal
stresses and deformation generated in the castings
weakens strength of part for further mechanical
processing. To improve and sustain quality of
parts produced in the centrifugal casting. it is
necessary to minimize and control parameters
such as thermal stresses, mechanical deformations
which affects quality of the castings. Therefore, It
is necessary to carry out thermal structural coupled
analysis of centrifugal casting process to study the
influence of process parameters such as preheating
temperature, pouring temperature on the stress
concentration.
Boundary Conditions: The thermal boundary
conditions such as preheating temperature,
pouring temperature and surface temperature of
die are used as in the case of transient thermal
analysis. Whereas the additional structural
boundary conditions applied are as follows.
1) Rotational Velocity = 540 Rpm
2) Displacement on inner walls of die and flange
supporting disc = 0 (Fixed Wall)
3) Torque =106.157N.m
The influence of process parameters such as
preheating temperature and pouring temperature
on stress concentration can be studied from the
following set of tables.
Equivalent Stresses
(MPA)
339.08
338.6
338.13
337.66
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7 Kulkarni AV et al.

Therefore, 270°C is selected as effective of pouring temperature on the Equivalent stress

preheating temperature from the set and can be verified by keeping preheating temperature
temperature below 270°C is avoided so as not to constant and repeating same procedure for set of
affect maximum heat flux rate identified with pouring temperature
transient thermal analysis. Similarly, the influence
S. No. Preheating Pouring Temperature Equivalent Stress
Temperature (°C) (°C) (MPA)
1) 270 1400 337.17
2) 270 1350 325.4
3) 270 1300 314.22
4) 270 1250 302
Table 8.Pouring Temperature vs Equivalent Stresses

The thermal stresses induced at 1250°C are low 1200°C and it is pourable only above 1250°C.
but it cannot be selected as ideal pouring Therefore, 1300°C is selected as effective pouring
temperature, because the Grey cast iron melts at temperature.

Figure 8.Equivalent Stress vs Preheating Figure 9.Equivalent Stress vs Pouring

Temperature Temperature

In the above analysis, it is observed that Thermal dependent on pouring temperature. whereas,
Stresses induced in the centrifugal process are the Change in Preheating temperature do not cause
functions of process parameters such as preheating major change in equivalent stresses as compared
temperature, Pouring temperature and surface with change in pouring temperature. Hence, It can
temperature of die. Thermal stresses vary linearly be concluded that lowering both preheating and
with preheating and pouring temperature. It should pouring temperature would induce less thermal
be noted that pouring temperature play vital role in stresses, in casting part provided that maximum
controlling thermal stresses as the amount of heat heat flux rate is maintained throughout the
generated inside the die is predominantly solidification process.
S. No./ SET Preheating Pouring Equivalent
Temperature(°C) Temperature(°C) Stresses(MPA)
1) (SET A) 300 1400 339.08
2) (SET B) 270 1300 314.22
Table 9.Comparison of Process Parameters with Analysis Results II

The following shows the finite element analysis loads and large amount of heat generated in
(FEA) results in terms of equivalent stresses centrifugal casting process. The results below are
generated in the cylinder liners during the obtained for in use and analyzed process
manufacturing process due to applied thermal parameters namely (SET A) and (SET B).

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Kulkarni AV et al. 8

Figure 10.Equivalent Stresses for set A Figure 11.Equivalent Stresses for set B

Cylinder Liners with Centrifugal Casting use process parameters (SET A). The following
Defects figures show the defects free cylinder liners
The following figures show the cylinder liners manufactured at analyzed process parameters
with centrifugal casting defects manufactured at in (SET B).

Figure 12A Figure 12B Figure 12C

Figures 12A, 12B, 12C.Cylinder liners with centrifugal casting defects

Cylinder Liners without Centrifugal Casting Defects

Figure 13A Figure 13B Figure 13C

Figures 13A, 13B, 13C.Cylinder liners without centrifugal casting defects

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9 Kulkarni AV et al.
Conclusion
The centrifugal casting process can be optimized
to improve the quality of products with process
parameters such as preheating temperature,
pouring temperature, surface temperature of die
during solidification process. Decrease in pouring
temperature increases rate of solidification as
thermal gradient available for heat flow during
pouring conditions becomes higher and also
reduces solidification time & minimizes thermal
stresses induced in die. Whereas by decreasing
preheating temperature of die the surface
temperature of casting rotating inside cylindrical
die also decreases during solidification process.
Therefore the maximum heat flux during
solidification of casting remains constant, which
results in uniform solidification of casting.
Uniform solidification of castings prevails in the
production of parts having high mechanical
strength due to proper reinforcement and uniform
distribution of material particles on the surface
walls of cylinder liner in the current case. Thus, by
controlling maximum heat flux flow throughout
solidification process and thermal stresses induced
in the casting the centrifugal casting defects such
as segregation, shrinkage porosity can be reduced
to avoid catastrophic failure of defective parts.
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