Zero Casting Scab Defect in Wheel Hubs

Abstract

Jobbing Foundry industries suffer from heavy rejection because of the batch quantity of the customer casting schedules and the number of part verities according to customers' projects. while development time the part is proven by all foundry processes but at the time of the huge production batch as per sudden customer demand facing issues mostly in Green sand molding defects like scabs or any other kind of defects are occurred related to sand. Mostly foundry defects sand related found because of process failed to follow, the castings that have arcs, taper, and sudden section changes areas are prone to scab kind of defects due to losing mold in a particular area, the customer does not accept such parts because they are out of specification according to standard and may have failure issues while promoting his work function after final assembly. This paper hopefully gives a process solution for such kind of Green sand-related defects. No of kinds defects related to sand casting but behind this defect have a lot of process parameters that need to be controlled if the required casting is defect free appearance, the process solutions are difficult tasks in foundries because reverse analysis needs to be done like detective all reverse analyzed parameters are may or may not be true because they are assumed only according to personnel technical experience so we are going ahead according to analyzed study and taking trails so trail may or may not give satisfactory results so that’s why it is a difficult task so request to your technical team to be present when the first trial is going on while the first period of development results trial may give satisfactory of unexpected delightful results so further trial may be neglect and serious production starts for a particular part.

In the foundry industries whenever shortcuts are followed in the process that time defects have occurred. The Hub kinds of parts have sudden area changes and due to heavy casting weights sleeves are introduced for feeding purposes this is the main reason because the front of the gating sleeve area is not getting adequate mold hardness.