STUDY OF PISTON SLEEVE MANUFACTURED BY SAND CASTING PROCESS TO REDUCE REJECTION RATE USING SIMULATION SOFTWARE

Gating layout of a casting is an important aspect of tooling development. It inverse decision regarding part orientation in mould, part line, cores, cavity layout, feeder, neck and gating system. An improper method layout leads either to poor quality or low yield, which affect the productivity. Gating design is mostly carried out manually, using 2D drawing of cast part. Then tooling fabricates the sample casting which undergo 3-4 trials, which involves lot of production cost in the form of wastage of man power, time and hamper the day to day schedule of the particular production. Computer simulation provides a clear insight regarding the location and extent of internal defects, ensuring right casting as first time and every time. The casting simulation software is used to study the simulation behavior of casting. It is expected that this work will be of immense important equally to the academicians, as well as, to the industrial design engineers. Final product should confirm the design requirement without internal defects.