Yield Improvement for Sand Casting Product using Casting Simulation Tool

Abstract

The sand casting process is extensively utilized to produce ferrous products, offering advantages such as lower manufacturing costs and the ability to cast all types of materials, making it a versatile method. However, the complexity of the process poses challenges, as issues related to the design of the gating and risering system can result in defects such as shrinkage, cold shuts, and porosity. These defects can lead to structural weakness, inaccurate product specifications, and increased maintenance and repair expenses. This study aims to establish the best gating and risering system for the product by evaluating the process using a casting simulation tool. The optimum casting yield of the product was proposed by adopting several modifications, including the quantity and position of the riser as well as the gating system configuration. The 3D product was modelled using CATIA software, and Altair Inspire Cast was used to simulate and analyze the casting process. The study identified three defects during the filling and solidification process, namely cold shuts, porosity, and shrinkage, as benchmarks to improve the casting yield. An improvement of 4.74% in casting yield while eliminating casting defects for the brake drum case study has been achieved by using the casting simulation tool. Ultimately, this study demonstrated the importance of a proper gating and risering system in improving the casting process, reducing defects, and producing high-quality products, as it could reduce maintenance costs and material waste.