, International Journal of Advanced Engineering Research and Studies E-ISSN22498974
Proceedings of BITCON-2015 Innovations For National Development National Conference on : Innovations In Mechanical Engineering For Sustainable Development Research Paper PREDICTION OF OPTIMUM POURING POSITION IN THE VERTICALLY PARTED AUTOMATIC FLASKLESS GREEN SAND CASTING PROCESS Raghwendra Banchhor1, S.K.Ganguly2 Address for Correspondence 1 Associate Professor, 2 Professor and Head, Department of Mechanical Engineering, Bhilai Institute of Technology, Durg, CG India ABSTRACT Casting defects causes losses for a foundry, loss of time for reworked item and loss of material for scrapped unusable products. Investigating the reason followed by eliminating the causes will reduce defect percentage and positively contribute to productivity. In the vertically parted automatic flaskless green sand casting process the pouring position of mould string is an important parameter to be decided before pouring the mould string to avoid casting defects like fins and metal run out. Fins and run-out are the casting defects which may occur due to mould separation caused by unbalanced metallostatic force of liquid metal. This study proposes a mathematical relationship to predict the optimum pouring position of the mould string with varying pattern plate utilization, sand metal ratio and metallostatic head in Disamatic moulding line. A table is presented to guide the operation team to predict the optimum pouring position KEYWORDS: Flaskless green sand moulding, Sand-metal ratio, Pattern plate utilization, Optimum pouring position. 1. INTRODUCTION established on the conveyor. The molds can now be Vertically Parted Automatic Flaskless Green Sand filled with molten metal and the poured molds will be Casting Process consists of a molding machine and moved forward on the cooling conveyor in the same mold transporting conveyor. It applies clay green pace as the fabrication of new moulds takes place. At molding sands mixtures consist of silica sand, clay the end of the conveyor the solidified castings are called bentonite and few other additives. Their main separated from the molds and processed further, component is relatively cheap silica (SiO2) sand, one while the sand is directed to the sand preparation the most common compounds on the Earth. The plant for reconditioning and reuse in the next cycles molding sand mixture is blown by means of of the molding process.[1-5]. compressed air into a rectangular steel chamber, 2. LITERATURE REVIEW squeezed to a mold by two patterns fasted to the two In the vertically parted automatic flaskless green sand opposed side plates of the chamber. After squeezing casting process the pouring position of mould string one of the chamber plates retracts and swings is an important parameter to be decided before upwards and the opposite plates pushes the ready pouring the mould string to avoid casting defects like mold out of the chamber on a mold transporting fins and metal run out. Fins and run-out are the conveyor. Here cores can be set automatically into casting defects which may occur due to mould the mold cavity while the next mould is about to be separation caused by unbalanced metallostatic force prepared. The above cycle repeats until a chain of of liquid metal. such molds closed-up to each other has been
Figure1: Optimum Pouring Position in Disamatic moulding line [7]
Fins mould. This occurs during the pouring or just after A thin projection of metal, not intended as part of the the pouring of mould. casting is called fin. In usually occurs at the parting 3. METHODOLOGY line of the mould or care sections. Mould and core The objective of this study is to establish a incorrectly assembled cause fins. Insufficient mathematical relationship to predict optimum weighing of the mould or improper clamping of the pouring position when pouring the mould string of mould again causes fins. various casting in Disamatic moulding line. The Run-out methodology used to develop the mathematical Run-out is a condition in metal casting in which model for optimum pouring position is shown in liquid metal escape out through the parting line of Figure 2. Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/223-226 Banchhor, et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
Figure 2. Flow chart for formulating a relationship for predicting optimum pouring length
4. DERIVATION OF MATHEMATICAL automatic mould conveyor should be greater than or
EQUATION FOR OPTIMUM POURING equal to horizontal pushing force due to metallostatic POSITION pressure of liquid metal in the poured mould 4.1. Expression for Horizontal Force on Mould FR S x FH due to Metallostatic Pressure: Where S is a factor of safety which is taking into FH = Horizontal metallostatic force account the internal mould gas pressure, pouring Wm = Width of the mould (meter) choke pressure into account. Hm = Height of the mould (meter) PPU x H A M 1 PPU = Pattern plate utilization factor L Sx g = Acceleration due to gravity (m/sec2) S SM HA = Average metallostatic height (meter) M = Density of the metal = 7000 kg/m3 M = Density of the metal (kg/m3) S = Density of Squeezed moulding sand = 1500 FH = M g (projected area of mould cavity occupied kg/m 3
by liquid metal) HA = Coefficient of Friction between mould string and
FH = M g (Wm x Hm x PPU) HA AMC (in worst case) = 0.25 S = Factor of safety (Assuming extra pressure in 4.2. Expression for Resistive Frictional Force excess of metallostatic pressure will normally not between mould string and AMC: exceed 20%) = 1.2 FR = Friction force between mould string and AMC = Coefficient of Friction between mould string and L 1.2 x PPU x H A 7000 1 AMC 0.25 1500 SM Wm = Width of the mould (metre) L PPU x H A 22.4 SM 4.8 Hm = Height of the mould (meter) SM L = Length of mould string between moulding 4.4. Range of Independent Variables machine and pouring position (meter) Range of average metallostatic height considering the VU = Volume Utilization factor of moulds safety margin of mould cavity from the edges of the S = Density of Squeezed moulding sand (kg/m3) = 0.1 to 0.4 meter FR = Coefficient of Friction x Normal Reaction Range of Sand Metal Ratio (SM) = 3 to 20 = x Weight of all empty moulds between Range of Pattern Plate Utilization Factor (PPU) pouring position and moulding machine = 0.2 to 0.7 Considering above ranges of matallostatic height, FR = (Wm x Hm x L x VU ) S g sand metal ratio and pattern plate utilization factor The Volume utilization factor of moulds is defined as Tables are prepared to find optimum pouring position the ratio of volume occupied by the compacted i.e. the distance of pouring ladle from the chamber moulding sand to the total volume of the mould front of moulding machine. 4.3. Expression for Optimum Poring Position To avoid separation of moulds in the mould string the resistive frictional force between the mould and
Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/223-226
Banchhor, et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
Table1 : Optimum Pouring Length
Length of Mould String Between Moulding Machine and Pouring Position "L" (meter)
Expression for pouring position : 1. Moulding solutions, www.disagroup.com 2. Disamatic moulding explained, L PPU x H A 22.4 SM 4.8 www.metaltechnology.com SM 3. Variation of green sand molding, Flaskless Expression for pouring position clearly molding, www.engineershandbook.com indicates that optimum pouring position 4. Vertical and Flaskless moulding, depends on metallostatic height, sand metal www.industrialmetalcasting.com ratio and pattern plate utilization. 5. DISA MATCH article by Michael Colditz, State To avoid mould opening by pouring operation of the art in the manufacture of flaskless, horizontally parted moulds18/06/2012 optimum pouring position should be taken into 6. Per Larson, Iron melt flow in thin walled section consideration. cast in vertically parted green sand mould, Following the proposed guideline during metal Industrial research project at DISA Industries, pouring surely prevents occurrence of casting Technical University of Denmark defects due mould separation caused by 7. Application Manual (2011), Sand Moulding metallostatic force of liquid metal. System, DISA 230-A, Reg. No. 9155 H 6910, Edition 11-04.
Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/223-226
Banchhor, et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
8. Serope Kalpakjian and Steven R. Schmid , "
Manufacturing Engineering and Technology ", 4th edition , Pearson,New Delhi,2013 9. Raghwendra Banchhor,S.K.Ganguly, Critical Assessment of Green Sand Moulding Processes, International Journal of Recent Development in Engineering and Technology Website: www.ijrdet.com (ISSN 2347 - 6435 (Online) Volume 2, Issue 4, April 2014) 90 10. Raghwendra Banchhor, S.K. Ganguly, Optimization in Green Sand Casting Process for Efficient, Economical and Quality Casting, Int J Adv Engg Tech/Vol. V/Issue I/Jan.- March,2014/25-29. Note: This Paper/Article is scrutinised and reviewed by Scientific Committee, BITCON-2015, BIT, Durg, CG, India
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