Project Name

1. E-Foundry Project Project Name Student Name: Degree, Year: Branch: Institute:

2. Part Model 140 140 80 40 70 80 40 20 20 60 40 80 Part Metal: Cast Iron Mold Material: Sand

3. Part Simulation (without feeder) Hottest Region

4. Feeder Design Diameter of Feeder = D, Height of Feeder = H = 1.5D Modulus of Feeder = M = = = 0.375/1.75 Modulus of Hottest Region = 256000 / 25600 = 10 mm Modulus of Feeder = 1.2 x Modulus of Hottest region = 1.2 x (256000/25600) = 12 mm From the two equations for feeder modulus, Feeder Diameter D = 56 mm Modified Surface Area of the Hottest Region = Surface area of hot spot region – Area of feeder bottom = 25600 – ( = 23137 Modified Modulus of Hottest Region = 256000/23137 = 11.1 mm The feeder has to be redesigned for the increased modulus of the hottest region.

5. Feeder Design Modified Modulus of Feeder = 1.2 x 11.1 = 13.3 Modified Feeder Diameter = 62.2 mm Modified Feeder Height = 93 mm Modulus of Feeder Neck (Connection to Part) = 1.1 x Modulus of Hottest Region = 1.1 x 11.1 = 12.2 mm Assume some height of the neck (say 10 mm). Modulus of neck = = == D/4 Equating the two modulus values, Feeder Neck Diameter = 48.5 mm Yield = Part volume / (Part + Feeder + Neck) volume = 490867/(490867 + 282588 + 18474) = 62%

6. Simulation with Designed Feeder Feeder D = 62 mm Feeder H = 93 mm Neck D = 60 mm Neck H = 10 mm Observation: Feeder is hotter than part hot spot. A small island of high temperature is still visible inside the part.

7. Simulation with Larger Feeder Feeder D = 75 mm Feeder H = 112 mm Neck D = 49 mm Neck H = 10 mm Observation: Feeder is hotter than part hot spot. There are no hot spots visible inside the part. Hence feeder design is ok.

8. Simulation with Smaller Feeder Feeder D = 50 mm Feeder H = 100 mm Neck D = 40 mm Neck H = 10 mm Observation: Feeder is less hot than part hot spot. This will work only if an insulated sleeve is placed around the feeder.

9. Comparison Feeder D = 50 mm Feeder H = 100 mm Neck D = 40 mm Neck H = 10 mm Feeder D = 75 mm Feeder H = 112 mm Neck D = 60 mm Neck H = 10 mm Feeder D = 62 mm Feeder H = 93 mm Neck D = 49 mm Neck H = 10 mm Conclusion: Design with larger feeder is recommended, since it shows no shrinkage defect part, and there are not additional item (sleeve) costs.