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ORGANIZER;CN=ESTAD 2023:mailto:info@metec-estad.com
LOCATION:Room 2
SUMMARY:An optimized feeder 3D-geometry for a ductile casting generated autonomously by the CSAT system
DESCRIPTION:In the solidification simulation of shape casting, many sophisticated commercial modeling packages are accurate enough to predict the shrinkage porosity in the modeling results. However, it is difficult to produce autonomously a precise shape and geometry of an optimized feeder to avoid shrinkage porosity from the results solely. 
In this study, a so-called “casting shape analyzing technique (CSAT)” was developed and applied for the prediction of the solidification time for castings with complicated shapes. Using this technique, an optimized feeder for a complicated shape of casting could be calculated and generated. This feeder design is part of the casting process control for producing a good quality casting without shrinkage defects during solidification. 
For casting with complicated shapes, the relationship between the shape factor and the mold constant was established. Using this equation, the relationship between the solidification time and the geometry of a shape casting was correlated. As a result, solidification time and a required feeder volume could be predicted for an arbitrary casting shape. In this technique, an exact volume of a feeder could also be derived from the magnification equation. The precise shape and volume of the three-dimensional feeder geometry were autonomously produced from the equation. 
Four different sizes of ductile caliper castings with the same shape were successfully validated using this technique. It accurately predicted the required feeder size for these four calipers. The method and procedure to predict the solidification time and required feeder size for castings with complicated shapes were proposed in this study eventually.

Keywords: process quality control, ductile iron casting, shape factor, mold constant, feeder design, shrinkage porosity.

CLASS:PUBLIC
DTSTART:20230615T145000
DTEND:20230615T151000
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