Casting Simulation of Air Disc Brake

Abstract: Casting Simulation software which have become popular tools for modern metal casting industries and foundries, are on the verge of becoming the epicenter of virtually replicating the process of casting and its optimization. Our aim is to combine and compare results from Casting simulation and FEA of Air Disk Brake, utilize these results to map parameters that affect the quality of Cast components to Structural analysis. This would help confirm the theory of - “if residual stresses induced in casting process play a major role in contributing towards failure of components in Air Disc Brakes”. The results obtained will also be used to improve castability and avoid expensive workarounds. The importance of this study can be emphasized by the fact that even after rigorous simulations in FEA, unexpected failures occur during physical testing and, it is a well-known fact that the form of physical testing is money and time-intensive. With help of the results obtained through this study, the resources invested in testing can be reduced, resulting in overall process improvement. Creo, Inspirecast, Nova Flow & Solid, Ansys Workbench, Compose were the tools used to achieve the stated objectives. Learning new software like Inspirecast and Nova was challenging as well as rewarding. The project yielded useful results and improved our ken about Casting Simulation and FEA. We were able to confirm the theory by analyzing the results, observing the trend, and corroborate the pre-existing information as well as speculations.