2025 - Sustainable Industrial Processing Summit
SIPS2025 Volume 14. Intl. Symp on Multiscale, Modelling, Nanotechnology and Modelling Materials
| Editors: | F. Kongoli, D. Bammann, R. Das, J.B. Jordon, R. Prabhu, A. Rajendran, P. Trovalusci, M. de Campos |
| Publisher: | Flogen Star OUTREACH |
| Publication Year: | 2025 |
| Pages: | 214 pages |
| ISBN: | 978-1-998384-64-8 (CD) |
| ISSN: | 2291-1227 (Metals and Materials Processing in a Clean Environment Series) |
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USING COMPUTER SIMULATION TO ELIMINATE DEFECTS IN DUCTILE IRON CASTINGS
Peter Futas1; Alena Pribulova1; Peter Blasko1; Jozef Petrik1; Marcela Pokusova2; Marek Solc1; Patrik Fedorko1; Marcin Brzezinski3;1TECHNICAL UNIVERSITY OF KOSICE, Kosice, Slovakia; 2SLOVAK UNIVERSITY OF TECHNOLOGY IN BRATISLAVA, Bratislava, Slovakia; 3AKADEMIA GÓRNICZO-HUTNICZA IM. STANISŁAWA STASZICA W KRAKOWIE WYDZIAŁ ODLEWNICTWA, Krakov, Poland;
Type of Paper: Regular
Id Paper: 24
Topic: 71
Abstract:
The production of quality castings requires the use of modern computer programs that serve to simulate foundry processes as a tool for optimizing proposed production technologies. This paper focuses on the analysis of a computer simulation concerning the casting of a brake disc at a Slovak foundry. Notably, this brake disc has experienced issues such as shrinkages and micro shrinkages, which adversely affect the internal quality of the casting. Through this study, we aim to enhance our understanding of these challenges and explore solutions to improve the overall quality of cast components, making the process more efficient and cost-effective. Defects were identified in the ribs located in the upper section of the casting beneath the feeders. To address this issue, a comprehensive computer simulation was conducted, replicating the actual conditions of the casting and solidification process. The results revealed that the initially designed gating system, along with its feeder configuration, was inadequate in preventing the formation of these defects.
In response, a new feeder layout was proposed, which successfully eliminated the defects based on the simulation outcomes. The input parameters for this simulation were meticulously set to reflect the actual requirements of the foundry closely. To facilitate this process, 3D models of the assemblies were created using SolidWorks CAD software, and filling and solidification simulations were carried out using the NovaFlow & Solid CV 4.6r42 simulation program. This approach ensured a thorough analysis and resolution of the issues at hand.