QUANTITATIVE MACRO DEFECT ANALYSIS IN SAND CASTING: 3D SIMULATION AND POROSITY ASSESSMENT IN ASHTRAY PATTERNS

Jibril Maulana, Universitas Negeri Malang, Indonesia
Muhammad Adjie P.W, Universitas Negeri Malang, Indonesia
Rachmanda M.H, Universitas Negeri Malang, Indonesia
Rifan Aliyudin F, Universitas Negeri Malang, Indonesia
Yusuf Maulana, Universitas Negeri Malang, Indonesia
Didin Zakariya Lubis, Universitas Negeri Malang, Indonesia

 10.21831/dinamika.v9i2.77486

Abstract


Simulation analysis and quantitative approaches have become very important in the foundry industry to improve product quality and minimize defects. This study aims to analyze macro defects, particularly porosity, in ashtray patterns produced through sand casting. A quantitative approach was used to identify and evaluate macro defects in the castings by utilizing 3D simulation techniques. This process involves taking macro images of the molded samples and then processing them to determine the porosity level. The porosity evaluation was carried out by comparing the simulation results with experimental data, thus enabling a more in-depth understanding of the factors affecting casting quality. The results of this study show the porosity formed by 3-dimensional simulation and the porosity percentage derived from statistical interpretation of macro photographs of sand casting materials. The findings are expected to make a meaningful contribution to the foundry industry, particularly in the effort to improve product quality through process optimization. This study also highlights the importance of quantitative and simulation approaches in analyzing and predicting casting defects, which can ultimately reduce production costs and improve product yield.

Keywords


3D Simulation, Macro Defects, Porosity, Quantitative analysis, Sand Casting

Full Text:

121-129 (PDF)

References


Blondheim, D., & Monroe, A. (2022). Macro Porosity Formation: A Study in High Pressure Die Casting. International Journal of Metalcasting, 16(1), 330–341. https://doi.org/10.1007/s40962-021-00602-x

Chadha, U., Dhaliwal, G. S., Sondi, N. J., Darar, S., Chen, Y., Ram Kishore, S., & Yang, W. C. (2024). Optimization of Process Parameters and Additives for Improved Part Quality in Sand Casting: An Overview. Journal of The Institution of Engineers (India): Series D, 0123456789. https://doi.org/10.1007/s40033-024-00686-9

Giovanni, M. T. Di, Menezes, J. T. O. D., Cerri, E., & Castrodeza, E. M. (2020). Influence of microstructure and porosity on the fracture toughness of Al-Si-Mg alloy. Journal of Materials Research and Technology, 9(2), 1286–1295. https://doi.org/10.1016/j.jmrt.2019.11.055

Ingle, P. D., & Narkhede, B. E. (2018). A Literature Survey of Methods to Study and Analyze the Gating System Design for Its Effect on Casting Quality. Materials Today: Proceedings, 5(2), 5421–5429. https://doi.org/10.1016/j.matpr.2017.12.129

Kuchariková, L., Tillová, E., Uhríčik, M., & Belan, J. (2018). Porosity formation and fatigue properties of AlSiCu cast alloy. MATEC Web of Conferences, 157, 1–9. https://doi.org/10.1051/matecconf/201815707003

Li, Y., Liu, J., Huang, W., & Zhang, S. (2022). Microstructure related analysis of tensile and fatigue properties for sand casting aluminum alloy cylinder head. Engineering Failure Analysis, 136(June 2021), 106210. https://doi.org/10.1016/j.engfailanal.2022.106210

Neuser, M., Grydin, O., Andreiev, A., & Schaper, M. (2021). Effect of solidification rates at sand casting on the mechanical joinability of a cast aluminium alloy. Metals, 11(8). https://doi.org/10.3390/met11081304

Rajkumar, I., Rajini, N., Alavudeen, A., Ram Prabhu, T., Ismail, S. O., Mohammad, F., & Al-Lohedan, H. A. (2021). Experimental and simulation analysis on multi-gate variants in sand casting process. Journal of Manufacturing Processes, 62(December 2020), 119–131. https://doi.org/10.1016/j.jmapro.2020.12.006

Raza, M. H., Wasim, A., Sajid, M., & Hussain, S. (2021). Investigating the effects of gating design on mechanical properties of aluminum alloy in sand casting process. Journal of King Saud University - Engineering Sciences, 33(3), 201–212. https://doi.org/10.1016/j.jksues.2020.03.004

Samuel, A. M., & Samuel, F. H. (1992). Various aspects involved in the production of low-hydrogen aluminium castings. Journal of Materials Science, 27(24), 6533–6563. https://doi.org/10.1007/BF01165936

Samuel, A., Zedan, Y., Doty, H., Songmene, V., & Samuel, F. H. (2021). A Review Study on the Main Sources of Porosity in Al-Si Cast Alloys. Advances in Materials Science and Engineering, 2021. https://doi.org/10.1155/2021/1921603

Sertucha, J., & Lacaze, J. (2022). Casting Defects in Sand‐Mold Cast Irons—An Illustrated Review with Emphasis on Spheroidal Graphite Cast Irons. Metals, 12(3), 1–80. https://doi.org/10.3390/met12030504

Singh, A. K., Soni, S., & Rana, R. S. (2020). A Critical Review on Synthesis of Aluminum Metallic Composites through Stir Casting: Challenges and Opportunities. Advanced Engineering Materials, 22(10). https://doi.org/10.1002/adem.202000322

Tammas-Williams, S., Withers, P. J., Todd, I., & Prangnell, P. B. (2017). The Influence of Porosity on Fatigue Crack Initiation in Additively Manufactured Titanium Components. Scientific Reports, 7(1), 1–13. https://doi.org/10.1038/s41598-017-06504-5




DOI: https://doi.org/10.21831/dinamika.v9i2.77486

Refbacks

  • There are currently no refbacks.


Copyright (c) 2024 Jurnal Dinamika Vokasional Teknik Mesin

Creative Commons License
This work is licensed under a Creative Commons Attribution 4.0 International License.

Lisensi Creative Commons 

Jurnal Dinamika Vokasional Teknik Mesin by http://journal.uny.ac.id/index.php/dynamika was distributed under a Creative Commons Attribution 4.0 International License.


 

 

 

in collaboration with:

 

 

View My Stats