• Shrestha Tiwari
• Dr. Pravin Kumar Singh
• Dr. Rohit Rajvaidya

Finite Element Analysis (FEA) has proven to be an effective tool for evaluating the thermal characteristics of mould casting processes. This paper presents an FEA-based investigation into the thermal behavior of various molten metals and alloys, including aluminum alloy, copper, alloy 617, and alloy 945, within a sand mould. Through thermal modeling, key parameters such as cooling curves and heat flow at the mould-metal interface were determined. The FEA results indicate that copper exhibits the highest heat flux, measured at 75.848 W/mm², reflecting a significant rate of heat transfer. In contrast, alloy 617 shows the lowest heat flux of 5.602 W/mm², and its maximum core temperature was recorded at 978.16K after 10 seconds. Alloy 945 demonstrated a core temperature of 1339.9K, with the interface region stabilizing at approximately 627.7K. The temperature variations and heat flux data obtained from these simulations are crucial for optimizing casting processes, improving casting quality, and reducing overall development costs. The detailed contour plots of temperature and heat flux offer valuable insights for the strategic placement of feeders and other feeding aids, which can enhance casting soundness and reduce defects.

- Finite Element Analysis (FEA), Thermal Characteristics, Mould Casting, Sand Mould, Cooling Curve Heat Flux, Temperature Distribution, Molten Metals, Aluminium Alloy

"FEA Simulation of Sand-Casting Process Using Ansys", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.11, Issue 12, page no.e743-e750, December-2024, Available :http://www.jetir.org/papers/JETIR2412484.pdf

"FEA Simulation of Sand-Casting Process Using Ansys", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.11, Issue 12, page no. ppe743-e750, December-2024, Available at : http://www.jetir.org/papers/JETIR2412484.pdf