Modeling and Simulation of Flywheel to increase Productivity by using Procast

Abstract

Pattern making is primary stage in the manufacturing of any casting. Here the dissertation work is carried out for Flywheel body casting of Sound Casting Pvt. Ltd., Kolhapur. CAD modeling is used to observe the core complexities for the Flywheel body pattern. Improper pattern and core design may increase complexity in mold and may affect the casting also. So these can be easily visualized by CAD software before manufacturing. Manufacturing of this pattern is to be done with the CAM software. While finishing of metal pattern the key issues arises in surface finish and depth of cut. So these can be solved by CAM software. Gating system design is done for the Flywheel body casting in order to get defect free components. As far as the casting of Fly wheel casing is concerned, finding the shrinkage is very important, as most of the casting defects occur at the hotspot. To avoid improper solidification of the casting the simulation software’s such as PROCAST is used. Hotspot is observed by PROCAST software and the feeder location is to be selected to avoid hotspot in the casting. The cooling curves are observed for the proper solidification of the casting.