| Popis: |
Modern casting manufacturing has taken a next higher level to produce cast products with minimum defects and higher productivity by employing the latest geometrical modeling representing the entire casting with its associated sprue, riser, and gating system. From the perspective of solidification principles, heat flow, fluid flow, and microstructural development during solidification are simulated to improve products’ quality with minimum rejections. The ’tooth point’ is a part made of wear-resistant manganese steel IS276 grade 3 used in the JCB bucket. The ’tooth point’ is part of an excavator bucket tooth mainly used to dig the soil to make pits, remove soil, and excavate in mines and hills. Tooth point encounters hostile conditions of wear, severe shear stress, sudden impact loading leading to fracture. Cracks found to be originating from the internal shrinkage cavities. The demanding specification requirement of the tooth point is primarily to limit the shrinkage porosity at all costs. The present research aims to make geometrical modeling of the entire casting, including sand mold, using SOLIDWORKS based on the actual dimensions of the part obtained from the primary manufacturer, Indy Engineering company. Simulation of heat and fluid flow, leading to complete filling, turbulence, and solidification, have been investigated to produce casting that facilitates directional heat flow and directing the hot spots and shrinkage to the risers. Shrinkage porosity eliminated by incorporating chills and no chills, thus enhancing the service part’s life. |
