Abstract
The quality of steel castings was analyzed in this paper through integrated simulations and experiments. The standard tensile specimens were considered as actual cast products. These specimens were prepared using a multi-cavity mold which was initially designed using standards and foundry practices followed by its optimization in casting simulation software MAGMA Soft. The specimens produced with the optimized mold were then tested under tension until fracture. Porosity predicted in casting simulations was integrated to finite element simulations of tensile testing. Simulated and experimental results were compared, discussed, and conclusions drawn. Some specimens indicated discrepancy in the simulated and experimental stress-strain behavior; however, porosity was not found responsible for this disagreement as confirmed through X-ray imaging and by comparing the simulated and actual porosities. It is concluded that the quality of cast specimens is compromised due to ineffective heat treatment which should be done in a more controlled manner for improved quality and performance of castings produced using multi-cavity molds.
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Acknowledgments
This research is funded by the National Science, Technology and Innovation Plan (NSTIP), Saudi Arabia, under grant number 14-ADV890-04-R. The authors appreciate the support from King Fahd University of Petroleum and Minerals and MAGMA to conduct this research work. The authors are also thankful to Dr. Sulaiman Pasha from KFUPM for training of ABAQUS and Dr. Bilal Shaer for his guidance and support during the actual casting runs at MASABIK foundry.
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Muhammad Azhar Ali Khan received his Ph.D. in Mechanical Engineering from King Fahd University of Petroleum and Minerals. His research interests include metal casting, finite element analysis, reliability, and additive manufacturing.
Anwar Khalil Sheikh is a Professor of Mechanical Engineering at King Fahd University of Petroleum and Minerals (KFUPM). He is the Director of Rapid Prototyping and Reverse Engineering Lab at KFUPM. His research interests include rapid prototyping and 3D printing, advanced manufacturing technologies, metal casting, and reliability.
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Sheikh, A.K., Khan, M.A.A. Mold design optimization and quality assessment of steel castings through integrated simulations and experiments. J Mech Sci Technol 34, 2975–2983 (2020). https://doi.org/10.1007/s12206-020-0629-y
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DOI: https://doi.org/10.1007/s12206-020-0629-y