Abstract:
Computer -aided casting design in widely used in casting industry by employing casting simulation programs. The programs normally simulate solidification behaviors of including flow of liquid metal, heat transfer, solidification profile and predicting shrinkage cavities. The result is better designs compared with the modulus method. Deciding to use the softwares is one of the most important problems for the industry. The concerns is about the costhenefit of the decision. The purpose of this study is to compare between the two design methods :the modulus method and the Computer -aided design method for the case of carbon steel casting. The scope of this research was to compare two pieces of castings ; T-shape and Slide Bracket. Materials used was low carbon steel JIS S25C cast in CO, sand moulds. Simulation software employed was MAGMASOFT. The results from the two design methods were compared with real casting. The design of gating system for unpressurized system are as follows : the ratio of sprue runner gate 1 :2 : 1.5 at parting line of mould. The design of feeding system by modulus method resulted in modulus ratio of lM, : 1. lM, :1.2MC The results revealed that the shrinkage cavity in T-shape casting with modulus design method appeared within the workpiece underneath the riser. For the one designed by computer software, the shrinkage cavity appeared above workpiece. For the Slide Bracket, shrinkage cavity in casting with modulus design appeared within workpiece and at the hot spot area with higher modulus. Computer -aided design helped reduce the above shrinkage mentioned above. The simulated results agreed well with experimental casting. The yields resulting from modulus method for T-shape and Slide Bracket castings were 69.01 and 56.46 %, respectively. The yields for T-shape and Slide Bracket castings using simulation software in design were 6 1.14 and 50.45 %.