Simulation-Driven Design Optimisation for Defect-Free Gray Cast Iron Brake Discs: An Industrial Case Study
DOI:
https://doi.org/10.37255/jme.v20i4pp136-142Keywords:
Gray cast iron, brake disc, shrinkage porosity, simulation, design optimization, casting defects, MAGMASOFT®️Abstract
Gray cast iron brake discs are widely used in automotive applications; however, micro-shrinkage defects that occur during casting can significantly impact their performance. This study addresses this critical issue by combining simulation and experimental validation to optimise the casting design. Using MAGMASOFT®️ simulation software, the formation of shrinkage porosities in an industrial brake disc was analysed, revealing that thermal concentration at L-junctions between the disc and flange was the primary cause. Three modified designs were proposed, incorporating fillet radii, increased flange inner diameters, and reduced chamfers to redistribute heat and minimise defects. Experimental validation confirmed that Design 3 (9 mm chamfer reduction + 130 mm flange inner diameter) successfully eliminated subsurface porosity without additional feeders or process complexity. This work demonstrates that minor geometric adjustments—rather than costly feeder additions—can effectively mitigate shrinkage defects in sand-cast brake discs, offering a practical solution for foundries.
Downloads
References
1. C.-P. Yeh, W.-S. Hwang, C.-H. Lin, Numerical simulation on hardness distribution for a FC250 gray cast iron brake disc casting and its experimental verification, Materials transactions 50(11) (2009) 2584–2592.
2. P. Futáš, A. Pribulová, G. Fedorko, V. Molnár, A. Junáková, V. Laskovský, Failure analysis of a railway brake disc with the use of casting process simulation, Engineering Failure Analysis 95 (2019) 226–238.
3. P. Futas, A. Pribulova, V. Sabik, J. Petrik, P. Blasko, M. Brzeziński, Elimination of Shrinkage in Ductile Iron Castings Using Computer Simulation of Casting and Solidification, Processes 12(3) (2024) 506.
4. X. Cao, Q. Zhang, J. Yu, X. Yu, Effect of compositional changes and heat treatment on microstructure and mechanical properties of gray cast iron, Journal of Materials Research and Technology 35 (2025) 5336–5352.
5. N. Kepczak, W. Pawlowski, Cast Iron Machine Tool Body Analysis: The Theoretical and Experimental Approach, Iranian Journal of Science and Technology, Transactions of Mechanical Engineering 44(2) (2020) 523–532.
6. M.A. Essam, A.Y. Shash, H. Megahed, E. El-Kashif, Effect of section thickness on microstructure and mechanical properties of compacted graphite iron for diesel engine applications, Heliyon 7(1) (2021).
7. Y.-l. Li, Q. Wang, R.-r. Chen, X.-x. Wang, Y.; Xia, G.-p.; Zhou, Y.-d. Qu, G.-l. Li, Influence of V content on microstructure and mechanical properties of gray cast iron for super-large cylinder liner, International Journal of Metalcasting 17(3) (2023) 1806–1814.
8. S. Du, C. Chen, R. Chen, Q. Wang, X. Cui, Q. Song, Influence of casting materials on the microstructure and mechanical properties of gray cast iron for cylinder liners, International Journal of Metalcasting 19(3) (2025) 1650–1662.
9. A. A247, Standard Test Method for Evaluating Microstructure of Graphite in Iron Castings, ASTM International, Pennsylvania (1998).
10. M. Drajewicz, P. Cichosz, S. Rudy, Coupled numerical simulations of the SIMCENTER 3D for casting equipment made of gray cast iron, International Journal of Mechanical Engineering and Robotics Research 9(10) (2020) 1360–1364.
11. L. Dobrzański, Fundamentals of materials science and physical metallurgy, Engineering Materials with Fundamentals of Materials Design, WNT, Warszawa (2002).
12. C. Labrecque, M. Gagne, Ductile iron: Fifty years of continuous development, Canadian metallurgical quarterly 37(5) (1998) 343–378.
13. M. Holtzer, R. Dańko, M. Górny, Influence of furfuryl molding sand on flake graphite formation in surface layer of ductile iron castings, International Journal of Cast Metals Research 29(1-2) (2016) 17–25.
14. H. Hou, G.W. Zhang, H.K. Mao, J. Cheng, A new prediction way to shrinkage cavity formation for ductile iron castings, Materials Science Forum, Trans Tech Publ, 2008, pp. 127–134.
15. L. Jiarong, L. Baicheng, Study of solidification shrinkage of ductile iron in dry sand molds, 材料科学与技术 15(03) (1999) 245.
16. P. Larrañaga, J. Gutiérrez, A. Loizaga, J. Sertucha, R. Suárez, A computer-aided system for melt quality and shrinkage propensity evaluation based on the solidification process of ductile iron, AFS Trans 116 (2008) 547–561.
17. A. Skoogh, B. Johansson, A methodology for input data management in discrete event simulation projects, 2008 Winter Simulation Conference, IEEE, 2008, pp. 1727–1735.
18. S.H. Davis, Theory of solidification, Cambridge University Press2001.
19. D.M. Stefanescu, Computer simulation of shrinkage related defects in metal castings–a review, International Journal of Cast Metals Research 18(3) (2005) 129–143.
20. S. Namchanthra, P. Phirommark, T. Phengpom, J. Priyadumkol, W. Wijitdamkerng, W. Chookaew, C. Suvanjumrat, M. Promtong, Numerical analysis of molten iron flow and heat transfer in plumbing casting defect detection using split tracking approach, Case Studies in Thermal Engineering (2025) 106287.
21. V. Šabík, P. Futáš, A. Pribulová, Failure analysis of a clutch wheel for wind turbines with the use of casting process simulation, Engineering Failure Analysis 135 (2022) 106159.
22. L. Sowa, Mathematical model of solidification of the axisymmetric casting while taking into account its shrinkage, Journal of Applied Mathematics and Computational Mechanics 13(4) (2014).
23. D. Joshi, B. Ravi, Classification and simulation based design of 3D junctions in castings, AFS Transactions 117 (2009) 7–22.
24. K. Singh, P.K. Reddy, D. Joshi, K. Subburaj, B. Ravi, 3D Junctions in Castings: Simulation-based DFM Analysis and Guidelines, InINAE International Conference on Advances in Manufacturing Technology, 2008.
25. J.B. Caine, Design of Ferrous Castings, (No Title) (1963).
26. W. Jackson, The design and properties of steel castings: Part 1—Engineering design and design for castability, Materials & Design 2(4) (1981) 187–195.
27. W. Jackson, The design and properties of steel castings: Part 2 processing and steel selection, Materials & Design 2(5) (1981) 230–235
