Mould Design Improvement and Flaw Analysis for Investment Casting Process using Numerical Computation with Experimental Validation
DOI:
https://doi.org/10.4314/njtd.v22i1.2910Keywords:
Altair Inspire Cast, Cold shut, Investment casting, Optimization, Shrinkage porosityAbstract
Investment casting is recognized for producing intricate shapes in a single process, eliminating the need for multiple manufacturing and assembly processes for welding and bending. However, challenges remain where flaws, such as shrinkage porosity can affect product quality. This research uses numerical simulations using Altair Inspire Cast to minimize flaws in the investment casting process for vehicle barrier support components made from stainless steel 304. This study begins with a numerical simulation of an existing mould design based on actual process parameters, followed by an experimental investigation of flaw occurrence and location. Several casting designs were tested, analyzing liquid metal behavior during filling and solidification. The initial design of Case 1a showed 455 mm³ of shrinkage volume, which was eliminated by rotating the casting parts 90 degrees in Case 1b. A further design improvement in Case 2a increased the casting yield by over 10% by reducing 50% the gating system height. However, without optimal parameters, cold shuts were introduced. Case 2b, which uses a shorter filling time of 10 seconds successfully mitigates the cold shut. Final design modifications (Case 3) were validated through actual fabrication, showing that flaw location could be predicted and process optimization achieved for higher-quality products.
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