Design & Analysis of Pure Iron Casting with Different Moulds

In the present work it has been shown that FEA software like ANSYS may play an important role in predicting cast defect before the actual casting. Transient thermal analysis and Couple-Field analysis in ANSYS can predict temperature distribution and thermal stress distribution in the casting after solidification very accurately. This fact has been proved by validating a transient thermal analysis which has been published in a reputed journal. After validating the thermal analysis, work has been extended to Couple-Field Analysis for thermal stress and shrinkage. After doing Couple-field analysis on sand mold, few modifications have been simulated and tested whether they are better than the configuration considered in the base paper. As first modification sand has been replaced by mullite and it has been seen that the mold shrinkage is less but the cast shrinkage is more. Thermal stress in the mullite mold is less than the sand mold. For the sand-mullite composite mold shrinkage is least as well as shrinkage for the cast is also least. But the thermal stress is more than the mullite mold.