Abstract:
Casting is a manufacturing process which is adopted to make different shapes; may experience defects like shrinkage, porosity and short metal filling, resulting in rejection of
casting. These defects are highly dependent on design of casting parameters (design of
gating and riser system) and reduced by improving design of casting parameters. In this
work High Manganese Steel (Hadfield Steel) beaters for secondary rotor of cement industry were produced in CO2 sand molding technique. Designing of Gating and Riser system
was done firstly using Traditional/Manual method and then by SolidCast Simulation
method. Castings were produced using both designs to verify the extent of defects and
their difference/improvement. Visual examination of castings designed by Manual
method showed major shrinkage defects whereas Software designed castings were quite
sound showing no shrinkage (macro porosity) and minor micro porosity was observed in
acceptable limit of casting class-III whereas castings are acceptable up to class-V. So, it
was concluded that SolidCast simulation software can shorten the lead time by eliminating
the tedious and time-consuming trial production as well as decrease the financial loss imparted in the trial castings stage. Also, the Casting quality was improved, and casting yield
was increased from 47% to 63%
