Optimization of Risering System and Its Experimental Validation Using Casting Simulation

Abstract

In the metal casting process, higher yield and minimum defects level are expected by the foundry industries. In the present global and competitive world metal casting industries needs to perform efficiently with a reduction in rejections. The primary goal is casting a product is the product is a defect-free component and the secondary goal in casting is to maximize the yield of casting by designing of gating system and find out optimum shape and sizes of feeders/risers, ingates, gates etc.  For obtaining better results, a lot of time, the number of iterations and trial and error is required on the shop floor for experimentation. Virtually simulated casting trials make certain that actual castings are defect free at first time and every time then after within a shorter lead time. Casting simulation provides reliable prediction of defects and good results even for complex shaped castings.  In this present case study, the primary goal is minimizing the shrinkage defect by designing the appropriate sized gating system for T section shaped casting by considering riser dimensions like height, diameter and also maximizing the yield of casting component using virtual simulation technique.