DISA

1
Abstract
MAGMASOFT
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
for a 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.
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.
Old Design
Results
Introduction

• 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

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.
Fig. Loaf Design
Our Design
Objectives

• 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

Fig. Fill Velocity
Fig. Modulus of Feeding
DISA
Fig. Temperature
Fig. Porosity
DISAmatic is a vertical casting process which the
part is being redesigned for. The figure below
shows the steps of the process.
Conclusions
Fig. Cluster Single Cap Design
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
Advisor Dr. Mark Plichta Acknowledgments Eben
Prabhu - Ford Motor Company, Paul Ballas - Ford
Motor Company, Pat Quimby
Team Members Wade Provoast MSE, Andrew Brouwers
ME, Kyle Peterson ME, Julie Emerick MSE, Molly
Crouch ME Sponsor Ford Motor Company