DISA

ResultsIntroduction

Team Members: Wade Provoast MSE, Andrew Brouwers ME, Kyle Peterson ME, Julie Emerick MSE, Molly Crouch ME

Sponsor: Ford Motor Company™

MAGMASOFT

Advisor: Dr. Mark Plichta

Acknowledgments: Eben Prabhu - Ford Motor Company, Paul Ballas - Ford Motor Company, Pat Quimby

Abstract

Conclusions

Objectives

Convert the loaf design poured in a green sand cope and drag mold to a cluster single cap design poured in a vertical

DISAmatic machine.

• Meet high integrity casting requirements with no visible porosity in specified machining areas

• Can be processed in a DISAmatic vertical mold configuration at Cleveland Casting Plant (CCP)

• Requires minimum machining to produce a finished cap• Meets dimensional requirements, minimum strength, and

lowest weight criteria specified in V-Engine Engineering (VEE)• Will be completed in solid models and evaluated in MAGMASOFT• Have gating and riser for a DISA process• Have material property predictions aligned with

VEE product specifications

MAGMASOFT is a casting simulation software that allows the testing of new designs by simulating the filling and solidification

of the molten metal within the mold. The software can be used fora multitude of casting designs and types of metals. MAGMASOFT outputs data such as cooling times and temperatures, filling velocity, porosity, feeding modulus, and fraction liquid. The data is then used

to analyze casting designs.

DISAmatic is a vertical casting process which the part is being redesigned for. The figure below shows the steps of the process.

• Design gating incorporates 12 near shape castings• Design risers to allow less than ~5% porosity in caps• Risers were designed to have a higher feeding modulus

than the caps to reduce porosity • Regulate flow to produce a velocity under 50 cm/s entering casting

The ductile iron main bearing cap for the crankshaft on the 5.4 liter engine has been determined to be

underdeveloped in terms of casting optimization. Due to the heavy machining required after casting, Ford desires a less expensive operation. Switching from a green sand

mold to a DISAmatic vertical mold will significantly reduce cost, as well as increase overall production.

Successfully converted from a loaf design to a cluster single cap tree design for usage in DISAmatic vertical caster. While minimizing porosity to ~5%, limiting velocity to 50 cm/s entering the caps, maintaining correct modulus of feeding, and maximizing the number of caps.

Fig. DISAmatic

Fig. Fill Velocity Fig. Modulus of Feeding

Fig. Temperature Fig. Porosity

Our Design

Old Design

Fig. Cluster Single Cap Design

Fig. Loaf Design