Simulation of Heat Flow in Computational Method and Its Verification on the Structure and Property of Gray Cast Iron

Problem statement: The solidification of materials depends on the cooling rate of the materials which is governed by heat flow in the mould and alloy composition. Solidification rate also affects the structure and properties of the materials. Approach: In the present study, the heat flow of cold set resin bonded sand mould was simulated using JL Analyzer FEM analysis software. To verify the model, the gray cast iron was melted at 1350°C temperature and poured into a resin bonded sand mould at 1300°C. Results: It showed that most of the heat-reserve at the junction of the mould which was nearer to the source of liquid metal and the lowest heat-reserve at the end of the mould. So, the solidification rate was very high at the end of the mould wall whereas it was comparatively low near the sprue of the mould. Conclusion: Finally, depending on the heat-flow through the mould, the solidification rate changed the microstructure from chill, mottled and gray cast iron and hardness changed from 95.1 HRB-78.78 HRB.