Analysis and Reduction of Casting Defects in Handwheel through Numerical Simulation

In today’s competitive world foundry industries must be efficient to operate with minimum rejections and they should be able to manufacture casting components in a short lead time. Casting manufacturing is a process in which the molten material such as metal, plastics, etc is poured into the specifically designed hollow cavity of desired shape, called the mould and the material is allowed to solidify. The solidified part is called as a casting, which is broken out of the mold to complete the process. Still few foundries are working based on trial and error method to produce their casting. Most of the foundries focus very less on rejections, as they are always oriented towards production urgency; hence they ignore the rejections and salvage the castings. Defect free castings with minimum production cost have become the goal of the foundries. To produce castings with minimum rejections casting simulations software can play a major role. casting simulation aids in the visualization of phenomena like a solidification of casting and mold filling, and helps to identify the occurrence of related defects like shrinkage porosity, and can be also used for the optimizing the design parameters to achieve a high quality yield.