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