Redesign and Analysis of Gating System of B515 Ford Drum

Abstract

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. Manufacturing of the any components firstly deal with design and analysis of gating systems of these components. Hence fore it is very important to study the gating system in any foundry industry. With competition within the foundry industry becoming fiercer and customers demanding higher quality components, shorter development times and more complex geometry, the use of computational simulation has become essential to stay competitive. In recent times the economic viability and increased ease of use has encouraged many larger foundries touse computational optimization software. Therefore these study presents through study of design of gating system. This design was further analyzed by simulation software ADSTEFAN which is more user-friendly and more acute to check whether it produces defect free ok castings or not. The design was finalized by analyzing the results obtained from ADSTEFAN simulation software and it was validated by actual production of castings and its testing using radiography technique. From this it is clear that, yield percentage and quality of castings has improved in considerable amount. This plays important role in economy of the Mahabal Industry. More Scrap weight, less yield percentage, allowable high soundness of part increases the cost of rejection. It also causes the environmental losses due to large scrap and rework. Rework of parts affects on the productivity. These are problems associated with present design of B515 Ford Drum gating system. The main objective is to increase the yield percentage and reduce the scrap weight by changing the design of current gating system of B515 Ford Drum. Hence this is an attempt to provide a better and efficient design of gating system.