Vol-2 Issue-3 2016 IJARIIE-ISSN(O)-2395-4396

“ Shrinkage
Porosity & Temperature
Distribution analysis of air cooled Cylinder
liner block of Grey cast iron –
ASTM class 35”
ParthLakum1 , R.D.Gondaliya 2 ,H.N.Chauhan3
1
Student M.E. CAD/CAM, A.I.T.S, Rajkot, Gujarat, India
2
Assistant Professor, A.I.T.S.D.S, Rakot,Gujarat, India
2
Assistant Professor 3 , A.I.T.S., Rajkot, Gujarat, India

ABSTRACT
The ma jor requirement of any foundry is to provide high quality casting products. Since the quality is depended
on thermal stress and solidification of the casting, a thermal analysis is a key area to work on. Heat transfer
coefficient is the vital element of any thermal analysis. Mould and the Casting interface is the most critical area
that gets affected during the solidification. Heat transfer ratio at the inter face will give an explanation about
temperature distribution and thermal stress analysis. Pro-Cast helps to understand heat flow of the casting. The
moment when the molten metal solidifies is the most important instant and at that time thermal analysis is
required to forecast the outcome of the casting solidification and to understand its behaviour..

Keywords: Casting, Temperature Distribution and Thermal Analysis, FEA, Pro -Cast.

1. Introduction:

Casting is one of the o ldest manufacturing processes that produce variety of do mestic and industrial
products. From melt ing the metal/alloy to machining of the final goods have many stages which affect the
final output in a different manner. The most important instant is when the object solidifies and goes throug h
various transient temperature flow variations that produce stress levels in different areas causing problems
and defects. [2]

Su Ling-Lu aims on the wet type cylinder liner produced by horizontal centrifugal casting and defects like
macro segregation and shrinkage holes. After simu lation and optimization of the solidification of the
WTCL model using casting software, temperature field can be found. Author investigates starting time for
water cooling, variation in mo ld wall thickness, thermal insulation cr iteria and coating thickness, through
which coating thickness is the most influential parameter on the defect area. After study, the optimu m
method was proposed [3]

Srinivasulu Reddy has used Pro-Cast software saying that Pro-Cast is a 3D analysis software and carries out
solidification and temperature analysis.He has worked in the object called casting wheel Rim [4]

P. Prabhakar Rao has worked on a crushing component and load bearing structure which requires good
mechanical properties and zero porosity. The co mbination of CAD technologies and process simulat ion
tools helps in achieving this in a given limited t ime span. This study helps in reducing scrap rates due to
unpredictable defects [5]

There is a lot of work already been done in the thermal analysis in the zone of casting. In this study a
review of such work has been prepared and steps to solve thermal analysis using ANSYS are discussed

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Thermal analysis software helps the tedious process of finding and understanding the heat flow of the
casting during the solidification procedure. To analy ze the process various programming tools like Pro -cast,
Opt-cast ANSYS etc are available to give out the results of thermal analysis. [1]

Here in this study we are concentrating on the Cylinder liner block of 85.5 mm used in Volkswegan Betel
Car engine.
In the Rajkot based Co mpany Esteem Auto Pvt. Ltd. this liner block is manufactured and the manufacturing
is done by sand casting which has a porosity defect.

Figure : 1 (Defected Cylinder)

Few input parameters of the simu lation are discussed here. Material properties of Grey Cast Iron ASTM
class 35 is shown below.

Table 1 : Material Properties of Cast Iron

Table 1 : Material Properties of Cast Iron

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Sand Properties of Silica sand is shown below in the table.

Property of Silica Sand Value

Conductivity 0.4 to 0.8 W/m K

Specific heat 1172.304J/ Kg K
Density 1520 Kg/m3
Table 2 : Silica Sand Properties

2. Methodology
Modelling of a casting Process [1]

In a regular casting simulation software the simulation takes following three steps:

Figure 2: (steps of analysis)

1) In Pre-Processor stage following jobs are done:

Figure 3:(Steps of pre-processing)

2) In the Main processing stage following jobs are done

Figure 4: (Steps of Main processing)

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3) In the Post processing stage following jobs are done

Figure 5: (Steps of Post processing)

Generalized idea of Procast simulation is given below.

Figure 6 : Pro-Cast Stages

1) After The 3D models of entire gating system and mold has been created the file type is chosen to open
it in the Pro-Cast environ ment for the further simulat ion. The file type may be STL,STEP, Parasolid
etc.
2) After opening the relat ive file for the simu lation one has to coincide the Casting 3D model with the 3D
Model of the Mold, which is known as Boolean operation of Cast & Mold.
3) Meshing is Generated of the Half sy mmetry assembly of the Cast & Mold. Basic Mesh in Pro -Cast is
done by the following manner
a. Surface Mesh : Meshing of the peripheral surface is done
b. Check Mesh : Meshing Quality in the mesh environment is checked weather it is up to the
mark or not.Is there any unmeshed surface left or not?
c. Correct Mesh : It corrects and solves the meshing irregularities and unmeshed surface.
d. After the surface mesh is completed the entire body is meshed inan environment called So lid
mesh or Volume Mesh.
4) The next environment is Cast. It has a provision of declaring the Material Specificat ion in our case is
Thermal Properties of the Cast Iron Class 35. Also some of the basic parameters are discussed below.
5) Material neeeds to be given their solidus and Liquidus temperature that has been specified in the table.
Also Body 1 & 2 that are Casting & Mold reapectively needs th eir initial temperature for the further
analysis as boundary Condition. It gives out the weight of the object on the base of the size of the mold
and density as 4.756 Kg which is close to actual weight
6) When one co incide Cast & Mold one get some interface between their respective boundary that
undergoes thermal distribution as well. Heat transfer Co-efficient at the cast mold interface is given to
the system which is taken as 500 W/m2 K.

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Here some of the input and output parameters of the research has been shown in the following diagram

Figure 7 : Input – Output Parameters

Here is the 3D model of the gating system created in CREO APDL workbench.

Figure 8 : 3D model of Gating System

Following are the surface and solid mesh geometry of the object created in Procast software.

Figure 9 : Surface Meshing Figure 10 : Volume Meshing

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Boundary Condition is applied now and Half symmetry Constraint is also selected because it takes lees time for
simulation for half of the object then the full it self

Air cooling is applied around the surface of the mold as shown.

Velosity required to fill in the cast in a minute is applied on the half circle Temperature range of 1350 °C and
Pressure of 1 bar is applied.

Figure 13 : Half Cymmetry Constraint Figure 14 : Air cooling Constraint

Figure16 : Velocity Constraint

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3. Temperature Distribution

Here after all the boundary Condition applied to the file, Temperature distribution is carried out

Following are the four iterations shown when the mould is filled 5%, 20%, 40%, and 90%. It shows the thermal
behaviour of the casting object.

Figure 18: Filling Iterations

Following is the final temperature distribution and thermal behaviour of the object when the mould os filled
maximu m

Figure 19: Temperature Distribution Analysis

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Following is the solidification simulation showing the start instanteneous time that has been observed 159.56
seconds

Figure 20: Solidification Simulation

4. Porosity Analysis

Following is the final porosity analysis report that shows that the porosity around the bore is measured. Also
tiny micro porosity measured in the fins

The amount of porosity measured is measured by the software is 2.69 % to be exact.

In shop floor trials in the Esteeme Auto Pvt.Ltd is also shows the porosity in side the bore which is not
negligeble.

Figure 21: Porosity Analysis and location Detection

5. Conclusion

Pro cast is one of the finest casting simulation software and simulation cuts down the shop floor trial that helps
predicting the amount and location of the porosity.

After performing simulation in pro cast, porosity amount has been found to be 2.69 % and It has been found
around the inner bore area which matches industrial output as well. Solidification simulation shows solidus time
has been observed as 159.56 seconds.

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Also the detailed temperature distribution of the object has been carried out.

References

[1] P. Laku m, RD. Gondaliya, IJ. Jadeja, Thermal Analysis of Casting using ANSYS: A Rev iew. Journal of
Production Research and Management. 2016

[2] Parth Laku m, Chauhan HN. Casting Simu lation using Pro Cast -A Rev iew. Journal of Production Research
and Management. 2016

[3] Su-Ling Lu, Fu-Ren Xiao, Shuang-Jie Zhang, et al. Simu lation Study on the Centrifugal Casting Wet-Type
Cylinder Liner Based on Pro-CAST. Appl Therm Eng. 2014

[4] K. Srinivasulu Reddy, Casting Simulat ion of Automotive Wheel Rim Using Procast, IOSR Journal of
Mechanical and Civil Engineering,2014

[5] Prabhakara Rao P, Chakraverthi G, Ku mar A CS, et al. Modeling and Simu lation of So lidification in Alloy
Steel Sand Castings. International Journal of Thermal Technologies (IJTT). Dec 2011

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