Nitte Meenakshi Institute of Technology

“ MATHEMATICAL MODELING OF CENTRIFUGE

CASTING TECHNIQUE”

PRESENTATION ON EVALUATION OF PROJECT VIVA-VOICE

M.TECH
in
THERMAL POWER ENGINEERING
VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM

BY

“SHIVAKUMARREDDY P N”
USN:1NT13MTP10 

UND ER THE GU IDANCE OF

Mr CHETHAN K S
A S S IS TAN T P R OF ES S O R
D EPARTM EN T OF M EC HANICA L ENGINEER IN G
N ITTE M EENA KS H I INS TITUTE OF TECH NOLO GY
YELA HANK A, BA NGA LORE-64
OVERVIEW

1 INTRODUCTION

2 LITERATURE SURVEY
3 OBJECTIVES
4 METHODOLOGY
5 MATHEMATICAL MODELING
6 RESULTS AND DISCUSSIONS

7 CONCLUSION
8 SCOPE FOR FUTURE WORK

9 REFERENCES

2
 INTRODUCTION

• The main principle that govern centrifuge casting are the same as that of centrifugal
casting process.
• For producing FGMs, centrifuge casting technique is one of the promising candidate
because of its good reproducibility, low production cost and specially to produce solid
cylinders.
• Centrifuge casting process need not have rotational symmetry and metal castings of
desired shapes can be manufactured with all the distinct benefits of castings produced
by a centrifugal casting process.

3
INTRODUCTION

Centrifuge casting machine

4
 LITERATURE SURVEY

Authors Year Conclusions

• They had worked on use of segregation of particle

without terming its FGMs.
1986 • The experiments carried out on the static castings
Nath and Rohatgi
revealed that due to density variation of the particle, there
is segregation of mica particles.

• Powder metallurgy technique involves the combination of

a material blended metals or ceramics, die compaction and
sintering.
Kawasaki et al 1990
• The material as deposited to the operation of forming
process of powder deposition as stepwise variation of the
particles is obtained in the compactness.
• They had developed the result of the heat transfer analysis
of centrifugal casting of metal matrix composites by 1-D
analysis in view of the thermo-physical properties.
Kang and Rohatgi 1996 • The particle is analyzed at every instant of time as a
function of temperature and position respectively.

5
 LITERATURE SURVEY

Authors Year Conclusions

• The author had investigated that the Sic particles on the

outer portion of the cast are smoothly uniform scattered
1997 within the matrix for a 30% quantity reinforcement.
Xiandong et al • Sic content shows gradation from outer boundary to the
inner boundary.

• They had worked on the process of centrifugal casting

which varies from the actual convectional cast processes.
Janco 1998 • The centrifugal force which acts on the molten metal was
used to spread the molten metal uniformly into the mold
cavities.
• The authors had worked on the manufacture of SiC/Al
FGMs.
• It was examined that the distribution of the SiC particle
Lin et al 1999 changed to a uniform content with fixed space from an
unconvectional pattern respectively.

6
 LITERATURE SURVEY

Authors Year Conclusions

• Centrifugal force is used for segregating the particles.

1991 • During mold rotation, the particle suspended in the liquid
Fukui
is subjected to both centrifugal and gravitational forces

• A Functionally Graded Material (FGM) is a class of

composite material, consisting of two or more phases,
Suresh and Mortensen 1998 which is fabricated with its composition and/or
microstructure varying in some spatial direction

• Centrifugal casting of aluminum melts containing

P.Samba shiva raju and suspended ceramic particles has been studied.
2000 • One dimensional heat transfer model with equation forces
S.P.Mehrotra
on a particles are formulated.

7
 LITERATURE SURVEY

Authors Year Conclusions

• They had studied a more practical model showing

variation in the quantity fraction of the particle across the
cast thickness with time.
Raju et al 2000 • They formulated a 1-D heat-transfer analysis mixing
variations in the thermo-physical properties on the matrix
due to particle movement.

• They had exclusively worked on the gradient slurry

disintegration and deposition process.
• FGMs with high and low Sic particle distribution were
Gupta et al 2002 observed and also wear resistance improved continuously
from low end to high end.

8
 LITERATURE SURVEY

Authors Year Conclusions

• The detailed knowledge of distributions of

Y Watanabe et al 2001 platelet orientation and particle size will help in
predicting the mechanical properties of the FGMs.

• had worked on the centrifugal casting process

where segregation of the particle takes place.
• 1-D transient heat transfer modeling with force
Panda, Mazumdar et al 2006
balance equation was done for the mold and the
cast alloy in order to analyze the temperature
distribution during solidification.
• Ceramic particles suspended in Aluminum melts
for vertical centrifugal casting of Functionally
Abdul Samad P.A.
Gradient Composite (FGC) have been studied.
Sandeep K. 2014
Dr. Shalij P. R.

9
 OBJECTIVES

1. To study the particle distribution in Functionally Graded Materials (FGM) along the longitudinal axis
of solid cylinders fabricated by centrifuge casting technique.

2. To develop a one-dimensional mathematical model for particle distribution based on particle size and
rotational speed of the mould for centrifuge casting technique.

3. To study the influence of different process parameters like rotational speed of the mold, particle size
and relative density difference between the particles and the melt on the segregation of particle.

4. To develop a mathematical model to describe the solidification time and the influence of other process
parameters on the solidification time and temperature distribution.

5. To study the MATLAB simulation program.

10
 METHODOLOGY

Experimental setup of Centrifuge Casting

Mathematical Modeling

Simulation using software

Results and Discussion

Centrifuge casting technique used for producing FGM is very effective and can produce solid
shapes when compared to conventional centrifugal casting process that can produce only hollow
symmetric shapes.

11
MATHEMATICAL FORMULATION

Centrifuge casting setup

= +⍴

= +

12
 MATHEMATICAL FORMULATION

Considering spherical particles in a matrix, the equation of motion for the particles in a
rotational stoke flow

F = -6πμbV = -6πμb

= -6πμb

Thus, the two equation of motion of each co-ordinates direction are given by

=-6πμ + ⍴

= -6πμb⍴ - 2

13
 MATHEMATICAL FORMULATION

The analytical solution is obtained

= exp- exp

Where,

k = and =

14
 MATHEMATICAL FORMULATION

Distance of the cylinder side(end), to the axis of rotation 30.00cm

Distance of the cylinder side(end), farther away from the

35.00cm
axis of rotation .
.
Density of the particle (AlB2) 3.19g/

Density of the liquid ρ (Al melt) (at 660˚C) 2.4g/

Rotational speed (rpm) 250 RPM

Viscosity of the liquid (at 660˚C) 1.38(mPa-s)

Average diameter of the particles 7.5 mµ

Variance 0.5 mµ

Some characteristic values of the parameters

15
 RESULTS AND DISCUSSIONS
150 150

Number of Particles
100 100
Number of Particle

50 50

0 0

30 31 32 33 34 35 30 31 32 33 34 35
Final Position [cm] Final position [cm]

2 secs 4 secs
150

CASE 1

Number of particles
100

Angular Velocity, ,
250
rpm
Viscosity, µ, mPa-s 1.38 50

Time of rotation,
2, 4 & 8
secs
0

30 31 32 33 34 35
Final position [cm]
8 secs
Particle distribution at different time intervals. 16
 RESULTS AND DISCUSSIONS
150 150
Number of Particles

Number of Particles
100 100

50 50

0 0

30 31 32 33 34 35 30 31 32 33 34 35
Final Position [cm] Final Position [cm]
2 secs 150
4 secs

Number of Particles
100

CASE 1
Angular Velocity, ,
400
rpm
50

Viscosity, µ, mPa-s 1.38

Time of rotation,
2, 4 & 8
secs
0

30 31 32 33 34 35
Final Position [cm]
8 secs
Particle distribution at different time interval. 17
 RESULTS AND DISCUSSIONS
150
Number of Particles 150

Number of Particles
100 100

50 50

0 0

30 31 32 33 34 35 30 31 32 33 34 35
Final Position [cm] Final Position [cm]
2 secs 4 secs
150

CASE 1

Number of Particles
100

Angular Velocity, ,
800
rpm
Viscosity, µ, mPa-s 1.38 50

Time of rotation,
2, 4 & 8
secs
0

30 31 32 33 34 35
Final Position [cm]
8 secs
Particle distribution at different time interval.
18
 RESULTS AND DISCUSSIONS
150
150

100
Number of Particle

100

Number of Particle
50
50

0
0
30 31 32 33 34 35
30 31 32 33 34 35
Final Position [cm]
2 secs Final Position [cm]
4 secs 150

CASE 2 100

Number of Particle
Angular Velocity, ,
250
rpm
50
Viscosity, µ, mPa-s 2.66
Time of rotation,
2, 4 & 8
secs
0

30 31 32 33 34 35
Final Position [cm]
8 secs
Particle distribution at different time interval. 19
 RESULTS AND DISCUSSIONS
150
150
Number of Particles

100

Number of Particles
100

50 50

0 0

30 31 32 33 34 35 30 31 32 33 34 35
Final Position [cm] Final Position [cm]
2 secs 150
4 secs

Number of Particles
100
CASE 2
Angular Velocity, ,
400
rpm
50
Viscosity, µ, mPa-s 2.66
Time of rotation,
2, 4 & 8
secs
0

30 31 32 33 34 35
Final Position [cm]
8
Particle distribution at different time
interval.
secs 20
 RESULTS AND DISCUSSIONS
150 150
Number of Particles

Number of Particles
100 100

50 50

0 0

30 31 32 33 34 35 30 31 32 33 34 35
Final Position [cm] Final Position [cm]
2 secs
4 secs 150

Number of Particles
CASE 2
100

Angular Velocity, ,
800
rpm
50

Viscosity, µ, mPa-s 2.66

Time of rotation,
2, 4 & 8
secs 0

30 31 32 33 34 35
Final Position [cm]
8
Particle distribution at different time secs
interval.
21
 RESULTS AND DISCUSSIONS
150
Number of Particles 150

Number of Particles
100 100

50 50

0 0

30 31 32 33 34 35 30 31 32 33 34 35
Final Position [cm] Final Position [cm]

2 secs 4 secs
150

Number of Particles
100
CASE 3

Angular Velocity, ,
400
rpm
50

Viscosity, µ, mPa-s 2.66

Time of rotation,
2, 4 & 8
secs
0

30 31 32 33 34 35
Final Position [cm]
8 secs
Particle distribution density change at different time interval. 22
 CONCLUSION

• Mold rotational speed directly affects the particle concentration gradient, so is the solidification
rate. Hence both are good parameters to control particle segregation.
• Analytical solution was carried out for centrifuge casting technique to study the particle
distribution in a fluid under centrifugal forces.
• Particle distribution is affected by the density difference between particle and fluid and the
denser particle will settle far from the center of axis of rotation.
• Particle distribution is affected by the viscosity of the fluid. As the viscosity of fluid is
increased the particle distribution rate decreases.

23
 SCOPE FOR FUTURE WORK

• In the present work, a mathematical model is developed to study the particle distribution in a fluid
using centrifuge casting technique. The influence of different process parameters like viscosity of
fluid, rotational speed of mold, particle size and relative density difference between the particles
and fluid is studied.
• The mathematical model developed during the present work do not consider the solidification of
molten metals under varying viscosity with respect to time and this can be incorporated for future
study to analyse particle distribution.

24
 REFERENCES
• Fukui, Y. (1991). Fundamental Investigation of Functionally Gradient Material Manufacturing
System using Centrifugal Force. JSME international journal. Ser. 3, Vibration, control engineering,
engineering for industry 34(1): 144-148
• Hur, B.-Y., S.-H. Park, et al. (2003). Viscosity and surface tension of Al and effects of additional
element. Materials Science Forum 439: 51-56.
• Lavine, A. S., F. P. Incropera, et al. (2006). Fundamentals of Heat and Mass Transfer. Sixth Edition
John Wiley and Sons Inc.
• Panda, E., D. Mazumdar, et al. (2006). Mathematical Modeling of Particle Segregation During
Centrifugal Casting of Metal Matrix Composites. Metallurgical and Materials Transactions
• Suresh, S. and A. Mortensen (1998). Fundamentals of functionally graded materials : processing
and thermomechanical behaviour of graded metals and metal-ceramic composites. London, IOM
Communications Ltd.
• Watanabe, Y., A. Kawamoto, et al. (2002). Particle size distributions in functionally graded materials
fabricated by the centrifugal solid-particle method. Composites Science and Technology 62(6): 881-
888.
• FGM research: design (Ogawa et al 2006), processing (Song et al 2006), (Zhang et al 2009), (Peng
et al 2007) and modeling (Panda et al 2006).

25
 REFERENCES
• Victor Birman, Larry W. Byrd, “Modeling and Analysis of Functionally Graded Materials
and Structures”, September 2007.
• J.W. Gao, C.Y. Wang, “Modeling the solidification of functionally graded materials by centrifugal
casting”.
• Yoshimi Watanabe, Akihiro Kawamoto, Koichi Matsuda, “Particle size distributions in functionally
graded materials fabricated by the centrifugal solid-particle method”, December, 2001.
• Michael M. Gasik, “Micromechanical modelling of functionally graded materials”.
• J N Reddy, “Thermomechanical behavior of FGMs”, August 1998.
• Song, C J., Xu, Z M.and Li, J G., "Study of in-situ Al/Mg2Si functionally graded materials by
electromagnetic separation method," Materials Science & Engineering, vol. 424, pp. 6-16, 2005.
• Lin, C Y., Bathias, C., McShane, H B., and Rawlings, R D, "Production of silicon carbide Al 2124
alloy functionally graded materials by mechanical powder metallurgy technique," Powder
Metallurgy, vol. 1, no. 42, pp. 29-33, 1999.
• Watanabe, Y, "Particle size distributions in functionally graded materials fabricated by the
centrifugal solid-particle method," Composites science and Technology, vol. 62, pp. 881-888, 2002.
• Kiran, Aithal, S., Vijay, Desai., Narendranath, S. and P G Mukunda., "“Effect of process parameters
on centrifugally cast Al-Si FGM”," Light metals, 2013.

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