Customers used to have defects parts in more than 50% cases during production of steel parts: cold cracks were appeared in the bottom part of casting. Main goals of this project were determination of causes of cold cracks in casting and suggestion of ways to improve casting process and remove of defects.
Stress analysis in ProCAST revealed that the high concentration of residual stresses in the zone of transition thin and thick walls were cause of cracks in casting. So we recommended to increase the thickness of wall, increase radius between thin and thick wall and also decrease diameter of bottom gate to reduce local overheating.
Customers completely removed these defects in casting after following our recommendations.