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Idp Project "Design Optimization in Gating: System" in "Shree Vallabh Alloy Steel Casting."

This document provides details about an IDP project on designing optimization in the gating system for Shree Vallabh Alloy Steel Casting company. The project aims to develop a methodology to optimize gating dimensions based on maximizing filling rate to produce castings free of defects. Two geometries - a lantern ring and a warm component - were selected for optimizing the gating system. Exothermic sleeves, which provide additional insulation, may be used with breaker cores in the risers. The project aims to reduce defects and optimize gating dimensions for maximum filling rate.

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68 views11 pages

Idp Project "Design Optimization in Gating: System" in "Shree Vallabh Alloy Steel Casting."

This document provides details about an IDP project on designing optimization in the gating system for Shree Vallabh Alloy Steel Casting company. The project aims to develop a methodology to optimize gating dimensions based on maximizing filling rate to produce castings free of defects. Two geometries - a lantern ring and a warm component - were selected for optimizing the gating system. Exothermic sleeves, which provide additional insulation, may be used with breaker cores in the risers. The project aims to reduce defects and optimize gating dimensions for maximum filling rate.

Uploaded by

ßlãçklïstęd ÑāwaßzåĐa Mìţž
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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INTRODUCTION

IDP project DESIGN OPTIMIZATION IN GATING


SYSTEM in SHREE VALLABH ALLOY STEEL
CASTING.
Submitted by: Arnav Patel (120070119088)
Meet Patel (120070119087)
Jay Patel
(120070119082)
Darshan Gandhi (120070119091)
Project guided by: Prof. U.B.Chaudhary

SHREE VALLABH ALLOY STEEL


CASTING
Shree Vallabh Alloy Steel Castings company is engaged in the
manufacturing and exporting of durable metal castings. With high
technology production machines, they have been providing castings
like Alloy Steel Castings, Plain Carbon Steel Castings, steel castings
etc.

Their Products are:


METAL CASTINGS:
Alloy steel castings
Carbon Steel Castings
Manganese Steel Casting
Nickel Based Alloy Casting
Stainless Steel Casting
Steel Casting

Project Definition
DESING OPTIMIZATION IN GATING SYSTEM
IN
SAND
CASTING
RELAVANCE:In Casting Process, gating system plays an
important role to produce a high quality
casting. A poorly designed gating system
results in casting defects. A gating system
controls mould filling process. The main
function of gating system is to lead clean
molten metal from ladle to the casting
cavity ensuring smooth, uniform and
complete filling. Hence to design a good
gating system one must know the
behavior of fluid flow during mould filling

Many products are made using casting


process as it is economical and has the
ability to produce intricate shapes. Casting
software can optimize the virtual castings
so that real castings can be produced
right first time and every time. This
however, requires a well designed
methodology
for
gating
system
optimization. For sound casting, we need
to optimize the gating system for a given
geometry of casting The literature
available on gating design optimization
recommends maximizing yield, minimizing
ingate velocity of molten metal, optimizing

There is no reported work based on


maximizing the filling rate of molten metal
in the casting cavity. Maximum filling rate
is critical in thin and long castings which
lose heat vary rapidly, and higher filling
rate helps to avoid defects like cold shut
and misrun. It is also useful wherein it is
required to increase the production rate of
casting.
So to Produce a casting that is free from
the pouring related defects and has
optimal gating dimensions based on filling
rate, there is a need to develop a
methodology that optimizes the gating

FOLLOWING ARE THE TWO GEOMETRY THAT WERE


ALLOCATED BY SHREE VALLABH ALLOY STEEL CASTING
COMPANY FOR OPTIMIZING THE GATING SYSTEM.

LANTERN RING
WARM

LANTERN RING

WARN COMPONENT

EXOTHERMIC SLEEVES
Hollow cylinder made of moldable,
exothermic riser material which is inserted
into the sand mold and forms a sheath
around the cylindrically designed, open
riser.
The exothermic reaction is initiated by the
liquid metal.

The effect of the exothermic sheathes is


not to transfer heat to the metal, as is
often assumed, but mainly to provide an
additional insulating effect on the ignited,
hot, glowing inserted sheath. Exothermic
sleeves can be adjusted to suit the
corresponding castings and are often
combined with breaker cores.

FIGURE: EXOTHERMIC/INSULATING SLEEVE

Advantages of exothermic
sleeves
Reduction of heat transfer compared to
sand risers, allowing the use of smaller
riser heads.
Reduced casting contact area for easier
removal.
Reduction of piping and shrinkage.
Manufactured
to
closely
controlled
external dimensions to allow insertion into
a preformed mold cavity.

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