Casting Simulation of Bearing Housing Using Web based Software and SQC techniques for Minimal Defect.

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1 Casting Simulation of Bearing Housing Using Web based Software and SQC techniques for Minimal Defect. Mr. Shubham Sanjay Sorate 1 shubhamsorate6@gmail.com Ms.Priya Umesh Kanase 2 priyakanase205@gmail.com 1,2 UG(Mechanical engineering) student at TKIT,Warana-Nagar, Kolhapur,Maharashtra.India. Prof.Mahesh Sadashiv Sawant 3 Asst. Professor, TKIT,Warana-Nagar, Kolhapur,Maharashtra.India. mssawant@tkietwarana.org Prof.Bhushan Shankar Kamble 4 Asst. Professor, KITCoEK,Kolhapur, Maharashtra.India bhushansk83@gmail.com Abstract: In foundry there are different types of defects are produced due to the various reasons. Casting defect can negatively impact the bottom line of foundry. It is responsible for loss of profitability, quality level and productivity of component. Hence it is preferably necessary to reduce it as much as possible by appropriate analysis. This paper presents research work carried out in foundry to minimize or reduce casting rejection due to major defect. Study focused on analysis of Blow holes defect which contribute more in total rejection percentage. First of all we find out the all defects in casting and one of the most probable is the Blow holes. In Bearing Housing mainly some at particular place blow holes formation occur at the matching plates and after machining blow holes are open. On casting there is less number of vents are provided for escaping the trapped gas in the casting. After study of Bearing Housing we analyse that the present vents are less than required due to which amount of gas escaping from casting is less therefore permeability of casting is less. In casting simulation software like E-foundry require the casting material flow properties, material properties and pouring material and temperature of the molten metal.at which location the temperature is high, at this location blow holes formation is possible and taking its remedies to reduce this problem defect by using of the simulation software and analysis of rejection by using and SQC tools. Index Terms: Casting defects, Blow Holes, Causes, casting Simulation, bar chart, pie chart. I.INTRODUCTION- Casting is a manufacturing process where solid melted, heated to proper temperature and is then poured into cavity or mould, which contains it in the proper shape during solidification. Thus in single step, simple or complex shape can be made from any metal that can be melted. The resulting product can have virtually any configuration the designer desires. Casting is a process which carries risk of failure occurrence during all the process of accomplishment of the finished product. Hence necessary action should be taken while manufacturing of cast product so that defect free parts are obtained. Mostly casting defects are concerned with process parameters. Hence one has to control the process parameter to achieve zero defect parts. For controlling process parameter one must have knowledge about effect of process parameter on casting and their influence on defect. To obtain this should have overall knowledge about casting defect, their causes, and defect remedies one has to be analyse casting defects. Casting defect analysis is the process of finding root causes of occurrence of defects in the rejection of casting and taking necessary step to reduce the defects and to improve the casting yield. In this review paper an attempt has been made to provide all casting related defect with their causes and remedies. During the process of casting, there is always a chance where defect will occur. Minor defect can be adjusted easily but high rejected rates could lead to significant change at high cost. Therefore it is essential for die caster to have knowledge on the type of defect and be able to identify the exact root cause, and their remedies. E-Foundry is the foundry simulation tool which is developed by the IITB and E-Foundry team. By using of E-Foundry improved casting design and simulation of casting, and fast and reliable algorithms for 3D casting design, simulation and optimization. Features in E-Foundry-Metal casting are the most economical process for producing intricate parts with internal features. These are used in transport, energy, sanitary, machine tools, defence and other sectors. Most foundries, however, suffer, from poor yield (as low as 50%) and quality (over 10 % rejections). This can

2 significantly improved by computer simulation of casting process. The E-Foundry lab at IIT Bombay has developed advanced and intelligent algorithms for automatic methods Casting Simulation- is a powerful tool to visualize progressive solidification of molten metal inside a mould cavity. It helps in identifying hot spots (yellow regions), which manifest as shrinkage porosity defects. The defect is usually eliminated by connecting a feeder, which is designed to solidify later than the hot spot. It supplies liquid metal to compensate the volumetric contraction at the hot spot. Feeder is cut-off and recycled, hence its size has to be optimized to ensure high yield. II. LITERATURE REVIEW B. S. Kamble [1] studied that the Virtual Casting Simulation may used to assure sound quality of castings and yield optimization without carrying and charging out shop floor trails, it also helps to analyse and optimize feed ability of a casting during redesign phase. Naveen hebsurand et.al [2] observed that, the casting simulation essentially replaces or minimizes shop floor trials to achieve the desired internal quality at the highest possible yield. Mark jolly [3] introduced simulation at all stages of casting to reduce defects and increasing the productivity and probability of the foundry. The software directly affects the production cycle time, internal quality of castings and material utilization. C. M. Choudhari et.al [4] experimented the process of casting solidification is complex in nature and the simulation of such process is required in industry before it is actually exists. The defects like shrinkage cavity, porosity, and sink can be minimized by designing an appropriate feeding system to ensure directional solidification in the casting, leading to feeders. Major parameters of a feeding system include: feeder location, feeder shape and size and feed aids. In this study, the component suffered from shrinkage porosity defect leading to premature failure. It also subjected to incomplete fill due to sudden variation in thickness. Hence, it is necessary to redesign and redevelop the component. This attempt has shown significant improvement in the quality of casting by optimizing the location and design of feeder for defect minimization. Vivek V.Yadav et.al [5] carried out an systematic approach for minimizing blow holes in sand casting. Quality analysis using different quality control tools is carried out to identify the major defect and root causes. Mohamad Riyaz et.al [6] suggested that the computer aided casting simulation is essential tool for casting defect production and troubleshooting those defects and cast optimization. He also told about it helps to assure quality of casting and yield improvement without doing shop floor trials. P. B. Lagdive et.al [7] investigated that the program/code generated by using Generated Algorithm Technique can be used to obtain optimized riser size for every type of casting component. The genetic Algorithm method can be applied to any standard feeder shape as the volume and area can be calculated by geometrical formulae. Abhijeet B.Vante et.al [8] said that the producing casting of specified quality and scheduled time in challenge for every foundry industry. Defect free casting with improved quality gives competitive advantages in market. Companies are implementing various quality standards such as KAIZEN, 7QC Tools and TPM. P. G. Panchal, et.al [10] stated that various casting defects are produce because of poor design of gating and risering system.in ball valve component optimizes the gating and risering system based on CAD and simulation technology with the goal of improving casting quality and increasing casting yield

3 III. PROBLEM DEFINATION- Foundry producing casting is facing blow holes problem for bearing housing component. The maximum rejection is due to the blow holes defect which contributes up to 7 % from 13 % of total rejection. Presently foundry requires reducing the percentage of rejection of optimum level. V.PROCESS WORK 5.1 Study and analysis of casting process of bearing housing. First step in the work is to study and analyse the casting process for bearing housing.above fig.shows the flow chart of casting process which is graphical representation for identifying diiferent steps in manufacturing.casting process consists of the different steps such as sand preparation, core making, mould making and assembly, melting and pouring, knockout, fettling, inspecton and painting. Raw material Melting Pouring Fig.1. Blow Hole Defect in Bearing Housing. Sand prparation Assembly of moulds Knockout and fetling Core making Mould making Inspection and painting. Fig.4Flow chart of operation carried out for bearing housing 5.2 Experimental Work in Foundry- Fig.2. Location of Blow Hole Defect In Bearing Housing. IV. METHODOLOGY- Fig.3 Flowchart of Methodology The main objective to carry out this work is to minimize the rejection percentage in casting. In this work different casting defect are studied out by analyzing the procedure and providing solution. This study will defiantly be helpful in improving the productivity and yield of the casting. Another aspect is related with the hardness. When the mould is prepared that time its hardness should be approximately In this case study it is seen that at the time of rainy season the rate of humidity is more. When the mould is prepared that time there is less chance of moisture content in the sand. It is analyzed that when humidity is more and suppose the mould is stored for long time say 2-3 days that time there may be chance of increase in percentage in moisture. As the moisture is an important element as it affects many properties. The behavior of

4 water in sand mould is very complicated because the heat flow includes vaporization and condensation of moisture and this phenomenon has been well understood. Thus an analysis of heat and moisture transfer in a sand mould containing water is important both for control of solidification and prevention of casting defect. So in this project it is seen that there may be chance of moisture content due to humidity. This project provides solution that as per work load the mould should be prepared. The storing time should not be more. So the sand moisture and sand preparation is the most important aspect which should be taken carefully. As the sand required for the bearing housing is mostly dry, so there should be any percentage of moisture in the sand. It is shown that the likelihood of blow holes is greatly increased with decrease in sand particle diameter because escape of vapour to the atmosphere becomes more difficult at permeability. It is difficult to measure temperature and moisture distribution simultaneously particular time immediately after pouring. Computer simulation is useful to investigate the behavior of moisture in sand mould. This is also illustrating the objective of work. By the use of computer simulation, it can be analyzed. Hence in this work on solution provided and that is if proper dressing is applied to the core, then slowing down the rate of heating and reducing gas pressure. In this work it is seen that the permeability should improve which will help to escape gasses. There is another problem and that is sand wash, if the proper alignment of core is not achieved then there is chance of sand wash. If some sand remained in the holes like riser, vent then there is possibility of gas being entrapped and sand wash defect. Another problem related with casting is when vents are not provided to the casting then the gas entrapped on the mould is more. So we provide the solution to adding the vents to escape the gas from mould. Therefore special runners are provided to the realization of gas from mould from that the optimal design is prepared. VI. PROCESS OF USING E-FOUNDRY- STEPS- 1.preperation of Solid Model a cast part and save it as a STL file. 2.Browsing and uploading the casting model file. 3.Waiting till simulation results are displated. 4.Identifying hot spots. Desiding feeder size and location. 5.Modeling the part with feeder and saving as.stl file. 6.Simulating again and checking the location of hot spots. 7.If hot spots are present then doing again steps 4 to 6. 8.Hence Improved casting design. VII. RESULTS OF E-FOUNDRY CASTING SIMULATION- 7.1Bearing Housing without Gating and Riser system Fig5.3D top view bearing housing. Fig6. 3D side view bearing housing

5 From above figure is seen that the hot spot area at cope or at drag part.the percentage of the defects are produced in on the surface of the casting and bottom of casting is more due to various reasons..also the molten metal temparature also affects on the casting.the blow holes on bearing are somewhat are opened already and somewhat after machining.also the ventilation are not provided at that place the hots spot are generate rapidly,due to non releasation of gas from mould cavity and blow holes and other defects are produced. Remedies Providing Ventilation at critical places on cope and drag of casting,which takes the more gas release from the casting and lesser rejection rates. After providing the riser and runners in the system and spcial ventilation are provided to casting from that the hot spot area are decreases and the formation of blow holes are occured is less.the gas or hot spot are present in the gating system in that riser or in runner and ventilation.thatswhy the gas entraped in the mould getting lower side and improved casting design and optimized casting. VIII. REPRESENTATION OF REJECTON RATE USING SQC TOOLS 8.1 bar chart rejection rate before and after providing solutions- 7.2Bearing Housing with Gating system- R e j e c t i o n A B C D E Fig7. 3D top view bearing housing with riser A,B,C,D,E IS BATCH OF 1000 PRODUCTS. REJECTION AFTER PROVIDING SOLUTION REJECTION BEFORE PROVIDING SOLUTION. A,B,C,D,E IS BATCH OF 1000 PRODUCT Fig10.Rejection quantity of 1000 product before and after solution. 8.2 Preparation of Cause and Effect (Ishikawa) Diagram:- The tree chart shows the various causes are related to formation of the casting defects in system.in that main parameters are man,machine, method,tooling and material and their sub causes. Fig8. 3D side view bearing housing with riser

6 foundry.the lesser rejection, more productivity of the product. 8.3 Pie chart of rejection percentages in the casting- BEFORE GIVING SOLUTION REJECTION RATE BLOW HOLES Fig9. Cause and Effect (Ishikawa) Diagram for Blow Hole Occurs in Bearing Housing. Table 1.Rejection rate before providing solutions Rejected Defects Quantity (No) Job Rejection % Blow holes Bad mould shrinkage % 12% 3% 3% 4% 1% 3% 2% 1% SCAB MISRUN SAND WASH SHRINKAGE BAD MOULD Fig11.Before giving solution rejection rate CORE BROKEN MISMATCH AFTER GIVING SOLUTION REJECTION RATE NO DEFECTS Bad core Core broken % 2% 3% 0% 3% BLOW HOLES SCAB mismatch MISRUN Hard Swell 1 o.1 84% SAND WASH SHRINKAGE NO DEFECTS Sand wash Fig12.Before giving solution rejection rate Table 2.Rejection rate after providing solutions- Rejected Defects Quantity Job Rejection % Blow holes Scab Misrun Sand wash From the bar chart are shows that the rejection rate before and after solution are getting lower side and it is benificial to the foundry because the rejection rate may affect on the productivity of the The above pie chart gives us information about the percentage of defects are present in the casting of lot of 1000 products.before providing solution the percentage of defects are more and after providing solution to foundry the percentage of defect goes on decreasing.from that pie chart we get that most probable defect is Blow Holes in the casting.thats why we are taking every information related with there causes and we provided some remidies over that problem.from this results the yield improvement in casting by 13%

7 IX. CONCLUSION Casting simulation is very powerful tool which is used to predict the growth of the process before physically performing the process.the major defect in casting is due to mositure content which forms the blow holes.therefore we have given solution to company to provide additional core ventilations to reduces the blow holes..also by use of simulation software reduces overall cost of developing the method for new casting by minimizing the time as well as labour involved in it.large number of trials can be performed quickly on simulation software and optimum results can be obtained which ultimately increase the profit margin of the foundry.the SQC tools provide effective information about quality.and from SQC tools we get quick information related defects.from this paper work we analyse the different type of manufacturing processes, various casting defects and for overcome that remedies.also we analyse the E-Foundry is the best tool for the simulation software, it is easy to use and optimum results are obtained. ACKNOWLEGEMENT The authours are greateful to the support provided by the Gnat Foundry, Shiroli MIDC, Kolhapur, Maharastra, India,in terms of providing necessary data and other relevant information about their product. and for supporting and guidance of the Prof. Bhushan S Kamble (KIT Kolhapur) and Prof. Mahesh Sawant (TKIET, Warananagar). All the simulation results in this paper were obtained by using web resources of IIT Bombay for online solidification simulation. Component By Using Web Based Online Simulation E-Tool International Research Journal of Engineering and Technology (IRJET),Volume-03,Issue Naveen Hebsur and Sunil Magshetty,July2014, Casting Simulation For Sand Caseting of Flywheel IOSR Journal of Mechanical and Civil Engineers (IOSR-JMCE),Volume-11, Issue-04, PP C.M.Choudhari,B.E.Narkhede,S.K.Mahajan,Jun 2016, Casting Design and Simulation ocover Plate Using AUTOCAST-X Software For Defect Minimization with Experimenatal Vailidation Science Direct (ICMPC 2014) 6. Manjunath Swamy H.M, J.R.Natraj, C.S.Prasad, October 2012, Design Optimization of Gating System By Fluid Flow and Solidification Simulation For Front Axle Housing, International Research Journal of Engineering and Development,e-ISSN; , Volume-4, Issue-6, PP B. Borowiecka and O.Borowiecka, March 2011, Casting Defects Analysis By The Pareto method Archives Of Foundry Engineering,volume-11,issue-3/2011,pp Aniruddha Joshi and L.M.Jugulkar,April 2014, IJMAPE Investigation and Analysis Of Metal Casting Defects And Defect Reduction By Using Quality Control Tools,volume-2, issue-4. Authors Profile Mr.Shubham S.Sorate UG(Mechanical engineering) student, TKIET Warananagar. shubhamsorate6@gmail.com REFERENCES 1. Vivek V. Yadav, Shailesh J Shaha,Jun. 2016, Quality Analysis Of Automotive Casting For Productivity Improvement By Minimizing Rejection,IJMPE,Volume-4, issue Nimesh.a.khirsariya,M.S.Kagthara,P.J.Mandalia, April 2014, Reduction of Shrinkage Defect in Valve Body Casting Using Simulation Software,IJESRT,ISSN: Bhushan Shankar Kamble,March 2016, Optimized Design of Risering system For Casted Ms.Priya U.Kanase UG(Mechanical engineering) student, TKIET Warananagar. priyakanase205@gmail.com Prof. Mahesh Sawant Asst. Professor, TKIET Warananagar. mssawant@tkietwarana.org

8 Prof.Bhushan S. Kamble Asst. Professor, KIT s College of Engg.Kolhapur bhushansk83@gmail.com