Paper Title
Defect Minimization in Cast Parts Using Computer Aided Simulation Approach
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Registration ID: IJNRD_310010
Published ID: IJNRD2510200
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Keywords
Defect Minimization in Cast Parts Using Computer Aided Simulation Approach
Abstract
Over the past two years (2023–2024), a total of 320 gear housings were manufactured at a precision casting unit located in Peenya Industrial Area, Bengaluru, Karnataka. Among these, 112 housings (about 35%) were rejected due to shrinkage porosity defects, which reduced the overall casting yield to just 52.8%. This high rejection rate caused a financial loss of₹18,75,000 during the period. Casting simulation studies confirmed that shrinkage defects in the flange roller castings originated from the existing casting method. The primary objective of this study is to reduce shrinkage porosity in flange roller castings using a computer-aided simulation approach to improve yield. A mixed research methodology was applied, combining simulation based optimization, theoretical study, and shop floor validation. Failure Mode and Effect Analysis (FMEA) was carried out to identify potential sources of shrinkage defects. Data for the study was collected through literature surveys, direct observations, review of foundry reports, and informal interviews. For analysis, tools such as cause-and-effect diagrams, Pareto charts, and why why analysis were employed.
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How To Cite (APA)
Sujith H J, Dr. Rajath H G, Dr. Chandan B R, Prashanth S, & Dr. Sadananda Megeri (October-2025). Defect Minimization in Cast Parts Using Computer Aided Simulation Approach. INTERNATIONAL JOURNAL OF NOVEL RESEARCH AND DEVELOPMENT, 10(10), b848-b862. https://ijnrd.org/papers/IJNRD2510200.pdf
Issue
Volume 10 Issue 10, October-2025
Pages : b848-b862
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Paper Reg. ID: IJNRD_310010
Published Paper Id: IJNRD2510200
Research Area: Science and Technology
Author Type: Indian Author
Country: -, -, India
Published Paper PDF: https://ijnrd.org/papers/IJNRD2510200.pdf
Published Paper URL: https://ijnrd.org/viewpaperforall?paper=IJNRD2510200
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