Engine Casting Heat Management
A new method has been developed in the conventional sand casting process to reduce the size of the riser. This method involves applying a cylindrical heater to the riser which is designed to continuously heat it. The results from the solidification analysis, conducted using the MAGMA software, have shown that the implementation of the heater allows the riser to solidify last, whereas without the heater, the riser solidifies before the cavity causing defects and misruns in the final product. The continuous heating method is a crucial aspect of the casting process and helps produce a high-quality, defect-free engine block.
As an engineering student, I always knew that gaining practical experience was going to be crucial for my future career. That’s why I was thrilled when I got the opportunity to intern at DCM Engineering Products, a company that specializes in solving problems in the casting industry. During my time there, I had the chance to work on a groundbreaking solution that aimed to reduce the size of the riser in the conventional sand casting process.
Our team was tasked with finding a new method that could improve the efficiency and quality of the casting process. After extensive research and experimentation, we developed a solution that involved applying a cylindrical heater to the riser. This heater was designed to continuously heat the riser, which would allow it to solidify last, reducing the chances of defects and misruns in the final product.
I was involved in the solidification analysis of the casting process. The results from the analysis showed that the implementation of the heater significantly improved the quality of the final product, producing high-quality, defect-free engine blocks. This innovative solution not only reduced the size of the riser but also increased the efficiency of the casting process, making it more cost-effective.
My role in the project was to assist with the design and testing of the cylindrical heater and to help interpret the results from the solidification analysis. Working with the MAGMA software was a new experience for me, and I was amazed by the power of simulation and analysis in engineering. I also had the opportunity to work with a talented and experienced team, who taught me new skills and encouraged me to think creatively.
In conclusion, my internship experience at DCM Engineering Products was a valuable and eye-opening experience. I learned about the casting process and solidification analysis, gained hands-on experience in engineering, and developed my problem-solving and teamwork skills. I am grateful for the opportunity to contribute to the development of a new method that will improve the casting industry and confident that the skills I learned will serve me well in my future career.