Optimization of Sand-Casting Process Parameters to Produce Quality Astm-A48 Class 35 Grey Cast Iron Pulleys: Simulation Results

Abstract

Green sand-casting process for ASTM-A48 Class 35 gray cast iron (GCI) was simulated in order to identify and validate appropriate process parameters to assure least possible casting defects, optimum microstructure, good machinability and mechanical properties for sound productions of medium–size pulleys. Chvorinov's rule and Wlodawer methods were used to calculate the values of parameters associated to the gating system and related components. Three dimensional model of the pulley was constructed using SolidWorks software. ESI ProCAST 2018.0 software was used as a numerical simulation tool to predict the
evolution of the filling state and temperature fields during solidification, the solidification at different positions of the casting, the temperature changes and the formation of gas porosity and shrinkage defects in the cast metal based on Niyama criterion. During simulations, the effects of dimensional parameters of mould and gating system on predicted outcomes were analyzed and correspondingly adjusted and customized in order to prevent occurrence of anomalies. Results of simulation trials showed a high level of confidence between the mould design criteria and process parameters. Correspondingly, optimum parameters leading to a cast metal with appropriate cooling time and free of porosity and shrinkage were identified and selected for appropriate mould design, what lead to an optimized mould cavity design and solidification process of the cast parts. The least possible casting defects, the optimum microstructure, good machinability and mechanical properties are expected in upcoming experimental validation tests.