1.
B. Dickinson, T. Midea, A. Adams
Vesuvius Inc. (Cleveland Foundry), USA
EVALUATING SEDEX* IRON FILTER PRINT DESIGNS – 30 YEARS LATER

2.
S. K. Subbarayalu, M. Manapuram
North Eastern Regional Institute of Science and Technology, India
DESIGN AND MANUFACTURE OF ENGINE PISTON CASTING OF INDIAN LIGHT MOTOR VEHICLE BY THREE-DIMENSIONAL PRINTING PROCESS: A STUDY

3.
J. Brence¹, S. Kastelic^{1 2}, A. Mahmutovič2, P. Mrvar³
¹Livarna Titan, d.o.o., Slovenia
²TC Livarstvo, Ljubljana, Slovenia
³University of Ljubljana, Faculty of Natural Sciences and Engineering, Slovenia
DESIGN OPTIMIZATION OF GATING SYSTEM FOR INSULATOR CAP FROM WHITE-HEART MALLEABLE IRON

1.
B. Dickinson, T. Midea, A. Adams
Vesuvius Inc. (Cleveland Foundry), USA

EVALUATING SEDEX* IRON FILTER PRINT DESIGNS – 30 YEARS LATER

2.
S. K. Subbarayalu, M. Manapuram
North Eastern Regional Institute of Science and Technology, India

DESIGN AND MANUFACTURE OF ENGINE PISTON CASTING OF INDIAN LIGHT MOTOR VEHICLE BY THREE-DIMENSIONAL PRINTING PROCESS: A STUDY

Abstract

India is the fourth largest light motor vehicle (LMV) manufacturer in the world. It produces around four million LMVs annually. An automobile is a wheeled vehicle that carries its own weight and transports from one destination to another. It consists of around 15,000 parts for its sub-systems like engine, transmission, suspension, brake system, electrical systems and chassis and body. The word ‘automobile’ is derived from Greek ‘autos’ meaning ‘self’, and Latin ‘mobiles’ meaning ‘moveable’. Automobiles may be classified from the point of capacity are two-wheelers, three-wheelers, light motor vehicles, and commercial vehicles (trucks and buses). LMVs are propelled by internal combustion engines (ICE) which are fueled by either petrol, diesel, gas, and electricity. ICE sub-systems comprise of cylinder block, cylinder head, piston with connecting rod, and crankshaft including camshaft and valves. The piston is the part of the engine which converts heat and pressure energy liberated by fuel combustion into mechanical works. An engine piston is the most complex component among the automobiles. Out of these components pistons are required high skill to design the casting which involves traditional manufacturing processes namely sand casting, pressure die casting, and squeezed casting. The traditional methods are time-consuming and more wastage of metal. So, there is a need to go for the latest manufacturing process called three-dimensional printing process (3DPP). It is an emerging manufacturing technology used to fabricate real-life parts, using CAD data by adding material in layer fashion in distinct forms (solid, liquid, and powder). 3-D printing technology can print an object layer by layer deposition of material directly from a computer-aided design model.
Most of the piston manufacturers have been following conventional methods for the manufacture of piston casting. Hence in the present work, an attempt has been made to study the design and manufacturing of piston casting by 3DPP.

Keywords: Automobile, Light Motor Vehicle, I C Engine, Piston design, 3 D Printing Process

DESIGN OPTIMIZATION OF GATING SYSTEM FOR INSULATOR CAP FROM WHITE-HEART MALLEABLE IRON

Abstract

The gating system for the vertical sand mold casting process must be dimensioned in such a way that the melt flows through it with as low turbulences as possible, that gases and ambient air are not trapped in the flow and that erosion of the sand mold does not occur during filling. The melt must also enter the casting cavity in a way that promotes directional solidification from the casting’s hot spot through the feeder neck up to the feeder.
During mass production, casting defects such as gas and shrinkage porosity, cold shuts, slag inclusion, hot tears, burnt on the sand, mold defects, etc. can occur. Nowadays, computer-aided simulations of filling and solidification are crucial for optimizing the parameters of the casting process and for predicting possible errors and risks before they occur. With them, we can determine the most optimal casting conditions already in the tool development phase and construct a suitable gating system, according to the specifications of the casting.
This work describes the gating system optimization of insulator caps, made from white-heart malleable iron. To reduce the large number of scraped castings in the company Livarna Titan, d.o.o. in Kamnik, a change was made to the casting tool based on “in-situ” thermal analysis and computer-aided calculations of filling and solidification using ProCAST simulation software package.

Keywords: gravity casting, gating system, malleable iron, simulation, ProCAST