Network Enabled Online Casting Simulationworkshop.nkn.in/2012/Document/slides/e-Foundry.pdf ·...

© Prof. B. Ravi, I.I.T. Bombay

E-Foundry Network Enabled Online Casting Simulation

Dr. B. Ravi Institute Chair Professor Mechanical Engineering Dept. Indian Institute of Technology Powai, Mumbai-400076

First Annual NKN Workshop, IIT Bombay, 31 Oct - 2 Nov 2012

© Prof. B. Ravi, I.I.T. Bombay E-Foundry Inauguration

© Prof. B. Ravi, I.I.T. Bombay

Aerospace Automobile Shipping

Sanitary

Machine Tool Farming Electrical

Home Fittings Defense

Energy

Medical Art

Machinery

Metal Cast Parts

© Prof. B. Ravi, I.I.T. Bombay Development Status

Iron melted and poured in sand molds in a Coimbatore foundry

Metal Casting Process

© Prof. B. Ravi, I.I.T. Bombay Indian Foundry Industry

Foundries = 4500

Employed = 1 million

Castings = 8 mT / year

Exports = US$ 1 b / year

World Rank = 2

© Prof. B. Ravi, I.I.T. Bombay Indian Foundry Industry

“By 2020 India will be a leading producer of quality castings…

We need better tooling and quality capabilities using CAD.”

Mr. Naresh Garg,

Past President, IIF

“Acute dearth of technical manpower is the biggest hurdle

confronting our foundry industry.”

Dr. APJ Abdul Kalam

Past President, India

“Indian foundries should shift from traditional

low-value products to high-value special products.

Key technology needed: process simulation”

Development Commissioner

MSME, New Delhi:

© Prof. B. Ravi, I.I.T. Bombay Casting Quality Issues

Feeder Molten metal contracts 3-6% while solidifying

Hot spot manifests as shrinkage defect

Prevented by a feeder; its size to be optimized

Hot spot (Defect)

Early freezing section

Feed path

© Prof. B. Ravi, I.I.T. Bombay

Limitations:

Too many unknown inputs

Long computation time (hours to days)

Difficult to learn and use even by technical persons

Expensive (hardware, software, maintenance, retraining)

Casting Simulation

Provides an ‘inside picture’ of temperature history

Enables defect reduction (by 50%)

Inputs required:

3D model of casting

material properties

process parameters

© Prof. B. Ravi, I.I.T. Bombay Motivation, Mission

Problem: how to make casting simulation technology

freely accessible and easily usable.

Solution: Online casting simulation with learning resources

Accessibility: By anyone, anytime, anywhere

Standard inputs: 3D CAD file created by any system

Low cost: Free access through NKN or Internet

Ease of use: Intuitive interface, minimal training

© Prof. B. Ravi, I.I.T. Bombay NKN E-Foundry Project

E-Foundry

Client-Server / Cloud-Computing

Casting Simulation

Lab

HD Video

Lessons Other institute Students,

Professionals

IIT Bombay Teachers & Researchers

NK

N/I

NTE

RN

ET

NK

N/I

NTE

RN

ET

Other Resources

& Tests

Applications and Benefits:

Teachers: Deliver more interesting lectures; engage students

Students: Learn and complex process; explore industry projects

Industry: Gain a better insight; improve casting quality & yield.

© Prof. B. Ravi, I.I.T. Bombay E-Foundry Lab: Flow Setups

Flow through Gating channels

Flow in mould cavity Recorded by data acquisition system

© Prof. B. Ravi, I.I.T. Bombay E-Foundry Lab: Moulding Unit

© Prof. B. Ravi, I.I.T. Bombay E-Foundry Lab: Melting & Pouring Unit

© Prof. B. Ravi, I.I.T. Bombay Video Content – Recording & Editing

© Prof. B. Ravi, I.I.T. Bombay E-Foundry Home (efoundry.iitb.ac.in)

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lessons – Introduction

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lessons – Science

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lessons – Engineering

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lessons – Technology

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lessons – Application

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lesson – Video

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lesson – Graphic

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Lesson – Quiz

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Resources

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Resources – Search

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Resources – Abstracts

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Resources – Case Studies

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Resources – Case Study

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Exercises

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Exercises

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Simulation Lab

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Simulation Lab – File Check

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Simulation Lab – Results

© Prof. B. Ravi, I.I.T. Bombay E-Foundry – Simulation Lab – CAD Files

© Prof. B. Ravi, I.I.T. Bombay Benchmarking: Desktop Simulation Software

Task / Time Taken AX FLOW+ NovaCAST SolidCast

Input Preparation 5 min 20 min 20 min

Solver Computation 15 min 35 min 10 min

Cast part: multi-junction casting

Overall size: 20 x 10 x 10 cm

Metal: Ductile Iron

Process: Green sand casting

System: i7 PC, 4GB RAM

OS: Windows 7 (32-bit)

Mesh size: 2.5 million

© Prof. B. Ravi, I.I.T. Bombay Benchmarking: E-Foundry Simulation Lab

Task / Time Taken CIT, Anand Gujarat

DKTE, Kolhapur Maharashtra

SGSITS, Indore Madhya Pradesh

CAD File Upload 21 sec 21 sec 19 sec

Solver Computation 16 sec 17 sec 15 sec

Server: i7 PC, 16 GB RAM

OS: Windows 7 (64-bit)

Part: Multi-junction block

CAD file size: ~ 100 kB

Mesh size: 1 million

Part simulation Part + feeder simulation

© Prof. B. Ravi, I.I.T. Bombay Simulation Benchmarking: E-Foundry Sim Lab

Server: i7 PC, 16 GB RAM

OS: Windows 7 (64-bit)

Part: Engine block

CAD file size: ~ 10 MB

Mesh size: 1 million

Engine block casting simulation

Task / Time Taken CIT, Anand Gujarat

DKTE, Kolhapur Maharashtra

SGSITS, Indore Madhya Pradesh

CAD File Upload 212 sec 142 sec 160 sec

Solver Computation 18 sec 17 sec 20 sec

© Prof. B. Ravi, I.I.T. Bombay Evaluation: Classroom versus Online Learning

Classroom Lessons (Aug-Sep 2012) Online Lessons (Oct 2012)

3D CAD Models Simulation – Optimization

Part Wall Thickness and Junctions Simulation – Benchmarking

Hole Features & Shape Complexity Simulation – Best Practices

Pressure, Velocity and Losses Simulation – Industry Survey

Turbulence and Fluidity Design for Quality – Manufacturability

Gas Evolution and Venting Design for Quality – Guidelines

Solidification Temperature and Time Design for Quality - Evaluation

Solidification Shrinkage

Microstructure & Cooling Stresses

ME 659 Advanced Manufacturing Processes: Casting Design and Simulation

Number of Students: 40

M.Tech Elective at IIT Bombay

© Prof. B. Ravi, I.I.T. Bombay Evaluation Criteria

Each lesson is evaluated by the following criteria (all in %):

Coverage (breadth): % of topics covered within a lesson

Understanding (depth): % of lesson clearly understood

Efficiency (effort): Lesson time / time required in learning

Effectiveness (retention): % remembered one week later

Overall Rating (satisfaction): Compared to an ideal scenario

Percentage to rating conversion: divide by 10. Ex. 30% = 3 points. Maximum = 10 points.

Ratings averaged for all students participating in the survey.

© Prof. B. Ravi, I.I.T. Bombay Evaluation Results

0 2 4 6 8 10

Effectiveness

Efficiency

Understanding

Coverage

Classroom

Online

Overall Rating 7.67

7.71

© Prof. B. Ravi, I.I.T. Bombay

Overall goal:

NKN-based online casting simulation and education

develop technical manpower for Indian foundry industry

make simulation technology easily and widely accessible.

Summary and Conclusion

Participation welcome:

Teachers: content; Students: benefit; Industry: collaborate

Progress so far:

GVM: 50x faster than FDM used in conventional software

E-Foundry Server with Classroom, Sim Lab, Library, Test Centre

Experimental facilities created to validate simulation results

Till date: 10,000+ visits, 250+ registered users, 650+ simulations

© Prof. B. Ravi, I.I.T. Bombay E-Foundry Team

© Prof. B. Ravi, I.I.T. Bombay Visit us today!

Real world: Cyber world: IDC-Hillside Road, IIT Bombay http://efoundry.iitb.ac.in