Estudo de caso de melhoria de rendimento metálico e redução de defeitos em peça fundida do setor automobilístico

Abstract

This work presents a case study about the production improvement of a part made of nodular cast iron in which there was a high cost of poor quality by a defect of shrinkage and sand inclusion, along with a low metallic yield of 48,5%. The method used to propose changes in the process, in order to increase metallic yield and reduce poor quality, was through casting simulation by the software Quikcast®, with this resource it was possible to understand the conditions of casting which matter the most to the result. This work started with the study of the current production condition of an automotive part produced by the company Multimetal Industria Metalúrgica Ltda. This initial study led to the discovery of the boundary conditions necessary to simulate the process. After analyzing the simulation results it was confirmed the viability of an increase in metallic yield as well as propositions for the root cause of poor quality by shrinkage based on the analysis of fraction solid and analysis of filling temperature. The root cause of the poor quality by sand inclusion was known, however, to make the necessary changes to the process, a validation for internal sanity was needed and the software was able to confirm it. The proposed solutions yielded positive results as there was a cost reduction for the production of the casting, this cost reduction was due to the increase in metallic yield of the casting along with a reduction of the index in poor quality.