Numerical Analysis

On Centrifugal
Casting process
 Acknowledgement
I would like to express my special thanks of gratitude to “HEL (Harsha
Engineers International Ltd.)” Who gave me the golden opportunity to do this
wonderful project of Numerical Analysis On Centrifugal Casting Process.
I would also like to thanks to my supervisor Mr. Devang Kiri (Manager at
HEIL) and Mr. C V Prajapati (Dy. General manager at HEIL) who made this work
possible.
I would also like to thanks my institute CSPIT- Mechanical engineering
(Chandubhai S Patel institute of technology) and my professor Dr. Dattatrey
Subedar for the continuous support through project.

Name of Guide from HEIL Name of Guide from CSPIT

Name:- Sanjay Korke

(General Manager) Name:- Dr. Dattatrey Subedar
(Associate Professor)
Name:- Chadubhai V
Prajapati
(Dy. General
Manager)

Name:- Devang Kiri

(Manager)
 Introduction

All component of
Cast product
centrifugal casting process
 Introduction

Finish product and particle segregation

 Introduction
• Defects in centrifugal casting are related to solidification process.
• Difficult to determine solidification time and temperature distribution by
experiment technique.
• Difficult to estimate the location and magnitude of defect.
• Basic parameters affecting solidification process and temperature distribution:-
• Heat transfer coefficient between cast-mould interface
• Thermo physical property
• Mold material
• Coating layer
• Pouring temperature
• Pre-heat temperature
 Literature review
• Heat Transfer Studies on Solidification of Casting Process.
(L. Anna Gowsalya and Mahboob E. Afshan – 2021)
– Heat-transfer model - metal shrinks due to air gap is formed - air gap is
obstruction for heat flow from the cast to mold - other parameter
responsible for quality of cast.
• Effect of cooling pattern on centrifugal casting mold stress–strain distribution
through computational fluid dynamics and finite element method analysis.
(E D Gopala Krishna, Shaik Shamshoddin, DV Raju and Raghu Ande -2018)
– 2D axisymmetric computational fluid dynamic – transient temperature
distribution in ductile material – mechanical analysis – predict stress and
strain acting on mold during cyclic thermal load – changing water flow.
• Numerical analysis of the Temperature Distribution in Centrifugal Casting.
(J. A. AKPOBI, I. D. ERHUNMWUN and T. A. OSUNDE – 2019)
– Mathematical modeling for conduction heat transfer in horizontal
centrifugal casting – predict temperature distribution through thikness.
• Estimation of Temperature Dependency of Molten Pure Metals Viscosities.
(Nobuyuki Takahira– 2020)
– The temperature dependency of the viscosity of molten metals.
 Literature review
• Numerical simulation of centrifugal casting for functionally graded metal
matrix composites.
(Sheeja Janardhanan – 2017)
– mushy state solidification characteristics in centrifugal casting are
numerically simulated using computational fluid dynamics - varying
rotational speed and volume fraction of reinforcement.
• Casting Defects and its Optimization Method in Centrifugal Casting Process.
(Shatrudhan Pandey and Sanjay Kumar Jha - 2017)
– Optimization method for eliminate centrifugal casting defects – micro
segregation – shrinkage porosity - coarse grain zone – taguchi method –
grey fuzzy method – computer simulation method.
• Effect of processing factors on the characteristics of centrifugal casting.
(Shubhashree Mohapatra, Hrushikesh Sarangi and Upendra Kumar Mohanty –
2020)
– Quality of cast – pouring rate – pouring temperature – mold temperature –
mold material – desired thermal gradient – cooling rate.
 Summary of literature review
• Main defects are generate in centrifugal casting is related to solidification
process and temperature distribution .
• To optimize defects we need to change the process parameter and combine
checked.
• Many analysis software are available in market for optimize centrifugal casting
solidification process.
• Heat flux, thermal gradient, stress – strain on die wall are concluding parameter.

 Gaps in previous research work

― Not to achieve optimize process parameter for alloy material
― Need for checking thermal effect on cast.
― Consider all parameter for optimizing (coating material, coating thickness,
mold thickness, cooling medium etc.)
 Problem Definition

Shrinkage porosity after m/c

Shrinkage porosity after m/c

 Problem Definition
• Goal
• Optimize Centrifugal casting process for tin-bronze (CuSn12Ni2)
material and reduce the rejection rate of final production.

• Objective
• Tin-Bronze is a critical material for solidification process, But
combination of all process parameter are not expectable for
manufacturing defect-less product. Numerical analysis is help to decide
proper combination of all parameter and optimize the process.

• Scope
• Numerical technique is help to optimize the process parameter and
proper combination of all parameter. It will help to select the process
parameter and manufacture defect-less product.
 Work progress
• G-factor theory:-

G.F =

Centrifugal force =

Gravitational force =

N=

Where:- m = Mass of pouring liquid

V = peripheral Speed
r = Radius
g = Gravity
N = rotational speed in rpm

• Suggested 50 – 100 G speed range for die cast (metal mold) and 25 – 50 G for
sand cast pots and shaped castings. Too high speed results in excessive stresses
and hot tears in outside surfaces.
 Work progress
• Mold Design:-

Where:- = Stress
T = torque
P = available power
G = Shear modulus
L = length of mold
r = Inner radius of mold
R = Outer radius of mold
 Work progress
• Thermal Property
Thermal Property
No. Name Value
1 Density (kg/m3) 8600
2 Viscosity (kg*s/m) 0.0176
3 Thermal conductivity (w/m k) 45
4 Specific heat ( J / kg k) 435
6 Molecular weight (Kg /K mol) 240.95
7 lattern Heat (J/Kg) 190000
8 Solidus temperature ( C ) 870
9 Liquidus Temperature ( C ) 1010
10 Pouring Rate (kg/s) 33.33
11 Pouring Temperature ( c ) 1150
12 Pre heat temperature ( c ) 270 - 300

• Geometrical Data
Geometrical Data
No Name Value
1 I.D of mold (mm) 300
2 O.D Of mold (mm) 450
3 Length of mold (mm) 1200
4 Angle of pouring (deg) 12
 Month wise progress of work

Duration → Nov Mar

Jul 22 Sept Jan 23 Feb Apr
Aug 22 Oct 22 22 Dec 22 23
22 23 23
Activities ↓

   
Literature
Survey/Revi
ew/Updates
               
   
Formulation
of the
Problem
               
   
Results and
analysis
               
   
Publication
               
   
Report
Writing
               
 Project Preliminaries
• NAME OF PROJECT:- THERORY OF CENTRIFUGAL CASTING &
EFFECT OF THERMOPHYSICAL -
PROPERTY
• COVERD TOPIC :-
» INTRODUCTION
» PHYSICS BEHIND CENTRIFUGAL CASTING
» TYPE OF DEFFECTS
» REASON FOR GENRATING DEFFECTS
» THERMAL EFFECT ON CENTRIFUGAL CASTING
» LITRATURE RIVEW
» REFRANCE
 Project Preliminaries
• Defects can be related to Pouring, Spinning, Temperature, Material, or Coating.

1) HOT TEARS
• The casting is not being cooled enough before extraction.
• The spinning speed is too high during solidification period.
• The mold bore diameter is uneven along the mold length.
• The mold was thickness is uneven along the mold length.
• Leaking endplates which can produce fins on both ends.
 Project Preliminaries
• First, check your water cooling nozzles. Are they free of debris and unblocked
so water can flow freely? Do you have enough water pressure to supply ample
water to the spinning die? If the answer to these questions is “no” then remedy
the problem!
• Second, check the fit of your endplates on your die. If there is not a good fit,
metal can seep through, creating a fin. A fin created in this manner can prevent
longitudinal contraction, which can, in turn, cause a hot tear.
• Once you are able to apply water to the spinning die at the correct pressure, cast
a part and increase the water cooling amount or the time that you apply the
water to your die.

• The casting is not being cooled enough before extraction.

• Spinning speed being too high during solidification period.
• Excessive machine vibration.
• The pouring rate is too high for thick-walled castings.
• The pouring temperature is too low for thin-walled castings or too high for thick
walled castings