Design and Development of Casting Parameters of High Manganese (Hadfield) Steel Casting by Using SolidCast Simulation Software

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%