SIMULATION BASED ANALYSIS OF SAND CASTING PROCESS PARAMETERS OF 46M n S i 4 ALLOY STEEL TRASH PLATE CASTINGS APPLICABLE FOR SUGAR FACTORY ROLLER STAND

Quality of casting is aff ected by number of defects due to different causes including casting parameters.This paper focus on the analysis of sand casting parameters for casting trash plate applicable for roller stand used in sugar factories.The problems in casting the trash plate from steel of varius grades are porosity,sand sintering,shrinkage,miss run, cold shut and other related defects.In this particular research manganes steel 46MnSi 4 was used as a material for the production of the mentioned plate.Thus the objective of thi s study is to analyze the parameters affecting the quality of the the trash plate casting in order to establish standars that provide sound casting.To carry out the research mixied (experimental and therotical) methods that include p hysical observation, p hotographic analysis, intrview, testing and simulation methods were used. Purposive and convenience sampling technique were used for sample selection and sampling. Modeling of trash plate and gating system elements were first developed using CATIA softwar e and simulation was carried out to show thermal history and solidification process of the plate using ANSYS software. The clay content and GFN of molding sand (silica) used were tested and result was found 6.983% and 49.805 respectively. The total solidif ication period of the trash plate was found as 769.05 seconds.