Advanced Casting Techniques for Complex-Shaped Components: Design, Simulation and Process Control

¹ Department of Mechanical Engineering, GLA University, Mathura, UP, India
² Institute of Aeronautical Engineering, Hyderabad
³ Lloyd Institute of Engineering & Technology, Knowledge Park II, Greater Noida, Uttar Pradesh 201306
⁴ Lloyd Institute of Management and Technology, Plot No.-11, Knowledge Park-II, Greater Noida, Uttar Pradesh, India - 201306
⁵ Hilla University College, Babylon, Iraq
⁶ Lovely Professional University, Jalandhar-Delhi G.T. Road (NH-1), Phagwara, Punjab ( INDIA ) - 144411.

^* Corresponding Author: Gaurav.pant@gla.ac.in

Abstract

The advancement of manufacturing technology has resulted in an increasing need for detailed, lightweight, and high-performance components with complicated geometries across many sectors. The emergence of advanced casting processes has been crucial in addressing these needs, as they provide the potential to manufacture components with complex geometries, enhanced mechanical characteristics, and minimised material wastage. The present study delves into the intricate domain of advanced casting processes, with a specific emphasis on the areas of design, simulation, and process control. The design of components with intricate shapes poses difficulties that conventional casting techniques encounter difficulties in surmounting. Simulation methods are crucial for accurately predicting the solidification and flow characteristics in casting processes, as this is essential for the production of components without any defects. Sophisticated simulation technologies, like as computational fluid dynamics (CFD) and finite element analysis (FEA), are utilised in advanced casting processes to model and analyse the intricate thermal and fluid dynamics phenomena that transpire during the casting process. This research provides an in-depth analysis of the role of simulations in enhancing the comprehension of solidification patterns, the identification of probable faults, and the optimisation of gating and riser designs to improve the overall quality of castings.