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Casting Defects and Root Causes for Engine Parts While Casting Process

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Casting Defects and Root Causes for Engine Parts While Casting Process Vaibhav Ingle. Int. Journal of Engineering Research and Application www.ijera.com ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -3) March 2017, pp.47-54 RESEARCH ARTICLE OPEN ACCESS Defects, Root Causes in Casting Process and Their Remedies: Review Vaibhav Ingle1 Madhukar Sorte2 1ME Mechanical Student, SCOE, Navi Mumbai, [email protected] 2Asso.Prof.in Mechanical Engg Department, SCOE, Navi Mumbai,[email protected] ABSTRACT Many industry aims to improve quality as well as productivity of manufacturing product. So need to number of process parameter to must controlled while casting process, so there are no of uncertainty and defects are face by organizations. In casting process industries are need to technical solution to minimize the uncertainty and defects. In this review paper to represent various casting defects and root causes for engine parts while casting process. Also provide preventive action to improve quality as well as productivity an industrial level. Keywords: Casting defects and their root causes, remedies for casting defects. I. INTRODUCTION II. MOTIVATION Casting is a manufacturing process, in Mostly casting defects are concerned with which a hot molten metal is use to poured into process parameters. Hence one has to control the a mold box, which contains a hollow cavity of the process parameter to achieve zero defect parts. For desired shape, and then allowed to solidify. That controlling process parameter one must have solidified part is known as a casting, Casting is knowledge about effect of process parameter on most often used for making complex shapes that casting and their influence on defect. The correct would be otherwise difficult or uneconomical to identification of the casting defects at the initial make by other methods. Casting is a process which stage is essential for taking remedial actions. carries risk of failure occurrence during all the Analysis of defects like shrinkage porosities process of accomplishment of the finished product. computer aided casting simulation technique is the Hence necessary action should be taken while most efficient and accurate method. The quality manufacturing of cast product so that defect free and yield of the casting can be efficiently improved parts are obtained. During the process of casting, by modifying like SQC DOE Method simulation there is always a chance where defect will occur. technique in shortest possible time and without Minor defect can be adjusted easily but high carrying out the actual trials on foundry shop floor. rejected rates could lead to significant change at high cost. Therefore it is essential for die caster to III. LITERATURE REVIEW have knowledge on the type of defect and be able Rajesh Rajkolhe, J.G. Khan conclude that to identify the exact root cause, and their remedies. various defect are generated in casting process In this review paper an attempt has been made to while manufacturing, defects may like as filling provide all casting related defect with their causes related, shape related, thermal related and other and remedies. defects by appearance. While performing various In a casting process, the material is first number of process parameters as trial and error heated to completely melt and then poured into a basis they find out various challenges and cavity of the mold. As soon as the molten metal is uncertainty in casting process. Such types of in the mold, it begins to cool. When the defects are developed poor quality and temperature drops below the freezing point productivity. To obtain high quality they was found (melting point) of the material, solidification starts. their remedies to minimize those challenges and Solidification involves a change of phase of the uncertainty also rejections. This action may helps material and differs depending on whether the to improve quality as well as productivity in material is a pure element or an alloy. A pure metal manufacturing industry. solidifies at a constant temperature, which is its Mr. Siddalingswami , S. Hiremath, dr, melting point (freezing point).An attempt has been S.R. dulange stated that various casting defects and made to analyze the critical defects and possible their causes. they go through a industry was remedial measures are suggested for cast masters to kirloskar ferros industry ltd. Solapur, they identify have a sound knowledge about such defects with an a defects for 4R cylinder block which they found a aim to minimize rejections rates. rejection rate was more than 40%. They also www.ijera.com DOI: 10.9790/9622- 0703034754 47 | P a g e Vaibhav Ingle. Int. Journal of Engineering Research and Application www.ijera.com ISSN : 2248-9622, Vol. 7, Issue 3, ( Part -3) March 2017, pp.47-54 conclude that , while production involve various analyze, also found the mold filling and parameter like pattern making, moulding, core solidification stage in casting parameters also making, and melting. A various defects like found filling behavior, solidification sequence, blowhole shrinkage, gas porosity, cold shot, sand thermal stress distribution in casting process for inclusion etc. are generated while casting process. achieve high quality and productivity. for improved their casting quality, they use product Alagarsamy are used trial and error process search analysis, inspection method, design method to solve casting related problem which of experiment method to found out their remedies helps find the defects and their root causes. Using a in casting process. powerful technique to mapping defects and finding C. M. Choudhari, B. E. Narkhede, S. K. questionnaires such as design of experiments Mahajan, are state that various casting defects can (DOE) for identify the defects and control the be minimize by simulation software basis, software variables in casting process. They also conclude the helps to improve quality of casting process and various defects in casting and root cause so also parameters. Utilization of methodology which they found their remedies to improve quality. involve four decision (1) orientation and parting Malcolm Blair, Raymond Monroe, line, (2) core print design, (3) feeder design, and Christoph Beckermann, Rishard Hardin, Kent (4) gating design. Experiment are perform for Carlson and Charles Monroe state that casting process by trial basis with help of simulation design are based on experience of designer who software which optimize faster and better result. It developed the design utilization factor of safety for helps to minimize the bottleneck and non value casting process. Also, utilizes unquantified factor added time in casting development as it reduce the such as shrinkage, porosity, also consider in number of trail for casting required on shop floor. casting. They predict the occurrence and nature of P. Shailesh, S.Sundarrajan and defects and effect on performance of casting. M.Komaraiah studied that optimization of process A.P.More, Dr.R.N.Baxi, Dr.S.B.Raju parameter in casting process for Al-Si alloy by Mechanical Engineering Department, G.H.Raisoni using Design of Experiments (DOE) method. It College of Engineering, reviewed that casting helps to improve the mechanical properties of yield defect analyze in initial improvement process to strength and density. The result is reducing the identify casting defects and their root cause. They pouring temperature and increasing the speed of die minimize the various casting defects their critical lead of casted component. They also studied component in casting process to improve quality. shrinkage characteristics and control the producing Identifying various defects and eliminates those defects casting. defects by taking appropriate corrective action to Dr. M. Arasu (Head department of achive higher productivity. foundry technology, PSG Polytechnic College) Elena Fiorese, Franco bollono and Gaiulio conclude that every casting process achieve to have Timelli department of management and cost effectiveness and high quality for customer engineering, stated that various process are point of view. They meant that cost effectiveness available for production of aluminium alloy, but means a strategy of utilization of raw material and significant role played by foundry process. they equipment to improve finish products with good highlight on multilevel classification of structural quality for defect free casting in casting process. defects and imperfection in aluminium alloy While in casting process of poorly maintained casting. The frist level of types of defects basis on equipment used then they affect to die as well as their internal, external and geometric. Second level casting parameters. So indirectly it fails to maintain distingwish on their metallurgical origin and third quality, and defect developed on external as well as level refer to the specific types of defects. In high internal side on casting components. pressure die casting required production rate up to T.R.Vijayaram, S.Sulaiman, A.M.S. 120 casting / hr. required high filling velocities of Hamouda, and M.H.M. Ahmad (Metal casting molten alloy up to 40 m/sec. (131 ft/sec)with industries) they was work on scrap rejection and significant turbulence in the flow. Solidification rework in manufacturing and state that for avoid takes place in few seconds and die is first contact the defects by implementation of various modified with a molten metal alloy temperature higher than technique which helps to eliminate the uncontrolled 700* C, (1292* F) and after 30-40 seconds, spray scrap and rejections. The modified technique such with a die relies agent at room temperature. as statistical quality control (SQC) to adopted for Solidification parameter is play main role to cooled developing metallurgical engineering foundry. the mold in casting so various defects can Guo-fa MI, Xiand-yu, Kuang-fei WANG, generated while differences in solidification time. Heng-Zhi FU, are applied numerical value as a M. Avalle, G. Belingardi, M.P. cavatorta, simulation for casting process. Types of defects R. Deglione Department of mechanical engineering like shrinkage, gas porosity, cold shut were politechno de Torino Italy, stated that the influence www.ijera.com DOI: 10.9790/9622- 0703034754 48 | P a g e Vaibhav Ingle.
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