Survey and Analysis of Sand Casting Design Methods
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Helsinki University of Technology |
Diplomityö
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Instructions for the author
Date
2006
Department
Major/Subject
Valimotekniikka
Mcode
Kon-80
Degree programme
Language
en
Pages
139
Series
Abstract
This Master's Thesis belongs to a project called "ICT in the new service concepts of foundry industry", financed by the Academy of Finland through the program KITARA. The object of this Thesis is to develop a clear and structured classification of the different physical laws of fluid mechanics and solidification affecting the casting process, together with an analysis of how these laws are applied in casting design. Furthermore, an analysis and classification of different design approaches based on these laws will be developed, giving special attention to the design of rigging (gating and feeding) systems. Because of the lack of resources and time, the scope of the Thesis is limited to sand casting. The methodological basis of this work is based on a survey and analysis of the existing guidelines and methods related both to the design of cast parts and design moulds, as well as the physical laws affecting the casting process. Using the results of this initial survey, a structured classification is presented, followed by a practical example of design casting optimization based on the analysed rules. The first part of the Thesis consists of a brief introduction of the work. Considering the current circumstances of the foundry industry, and more specifically the Finnish foundry industry, research in the field of design has appeared to be needed in order to improve competitiveness and face the competence of China and other low cost producers. One potential improvement is based in design optimization in order to decrease costs an increase quality. The second part presents a state-of-the-art in the field of sand cast design. A survey of different design rules and practices is presented, concerning cast part design as well as sand mould design. It is difficult to clearly differentiate rules for cast part design and those for mould design. In fact the part-pattern-mould design might be done in close cooperation among concerned parts in order to avoid eventual problems which are usually present. Gating and feeding systems are given special attention since that is an important source of potential improvement and optimization in sand cast design. Finally a synthesis of the analysed rules and methods will be implemented by means of ordered and structured lists and tables. These will be illustrated in the Appendix by a practical application example of the studied rules and methods for sand casting optimization, which was jointly developed by the Steels Founder's Society of America and the American Foundrymen's Society. The result of this work may be used for further research in the future.Description
Supervisor
Orkas, JuhaniThesis advisor
Coatanéa, EricMakkonen, Petri
