Design optimization of gating and feeding system through simulation technique for sand casting of wear plate

Casting is a manufacturing process to make complex shapes of metal materials; during mass production, we may experience many defects, such as gas porosity, pin holes, blow holes, shrinkages and incomplete filling that may occur in sand casting. Porosity is one of the defects most frequently encountered in ductile iron casting. Porosity impacts cost by scrap loss and limits the use of cast parts in critical high strength applications. The amount of porosity is closely related to the parameter of sand casting process. The gating/riser system design plays a very important role for improving casting quality. Many researchers reported that 90% of the defects in casting are obtained only because of improper design of gating and feeding system. The main objectives were to study the existing design of gating and feeding system, to optimize the gating and feeding system using Auto-CAST X1 casting simulation software, to prepare the sand mold and cast the part, to compare the simulated result and experimental results, to reduce rejection rate and to enable the company to again start the production.