Simulation Study of Sand Casting by Using Runner & Gates Modification in Gating System

Abstract

Sand casting remains a prevalent method for manufacturing complex metal components due to its cost-effectiveness and versatility. However, optimizing the gating system, particularly through runner riser modification, is crucial for enhancing casting quality and minimizing defects. This study employs computer simulation techniques to investigate the effects of various modifications in the gating system on the solidification behavior and quality of castings. Through numerical simulations using advanced software tools, different configurations of the gating system are analyzed and compared, focusing on parameters such as flow rate, velocity distribution, and solidification patterns. The results reveal insights into the effectiveness of runner riser modification strategies in reducing defects like shrinkage and porosity, thereby improving the overall casting quality. Additionally, the study explores the trade-offs between different modification approaches in terms of cost, complexity, and performance. These findings contribute to the optimization of sand-casting processes, offering practical guidance for engineers and manufacturers aiming to enhance product quality and efficiency.

Introduction

I. INTRODUCTION

1. Sand casting stands as one of the oldest and most widely used methods for the production of intricate metal components across various industries. its enduring popularity stems from its versatility, cost-effectiveness, and ability to accommodate complex geometries.
2. However, the quality of sand castings is intricately linked to the efficiency of the gating system, which governs the flow of molten metal into the mold cavity. inadequate gating system design often results in defects such as shrinkage, porosity, and misruns, which can compromise the integrity and functionality of the final product.
3. Optimizing the gating system, particularly through runner riser modification, has emerged as a critical strategy for improving casting quality and minimizing defects. runner and riser systems play pivotal roles in regulating metal flow, promoting uniform solidification, and mitigating defects during the casting process.
4. Strategically modifying the dimensions, shapes, and placements of runners and risers, engineers can tailor the flow dynamics and thermal characteristics of the molten metal, thereby optimizing casting quality and yield.
5. Despite the significant impact of runner riser modification on casting performance, the design process often relies on empirical trial-and-error methods, which can be time-consuming, costly, and prone to suboptimal outcomes. computer simulation offers a powerful alternative for comprehensively evaluating gating system designs, predicting solidification behavior, and optimizing process parameters in a virtual environment.
6. Through numerical simulations, engineers can efficiently explore a wide range of design variations, assess their performance under different operating conditions, and identify optimal solutions with enhanced precision and confidence.
7. In this study, we utilize advanced simulation techniques to investigate the effects of runner riser modification in the gating system on the quality and integrity of sand castings. by systematically analyzing various design configurations and their implications on flow dynamics, solidification patterns, and defect formation, we aim to provide valuable insights into the optimization of sand-casting processes.
8. The findings of this research are expected to inform practical strategies for enhancing casting quality, reducing production costs, and improving overall manufacturing efficiency in industries reliant on sand casting methodologies.

II. METHODOLOGY

A. Water Modeling

Many researchers have studied fluid flow in gating systems and mould cavities with the aid of transparent models usually made of Perspex or other plastics, in which the flow of metal is simulated by that of water. This method has the substantial advantage that the pattern of flow is clearly visible in all parts of the gating system and the cavity, but its validity, depends entirely upon the correctness of the assumption that the flow of water is closely analogous to that of the molten metal in simulation model.

Above all design velocity is shown in fig design 1 gate 1 velocity is 19m/s, and design 2 gate 1 velocity is 24m/s or design 3 gate 1 velocity is 26m/s, design 4 gate 1 velocity is 24.5m/s. design 1 gate 2 velocity is 17m/s, and design 2 gate 2 velocity is 20m/s or design 3 gate 2 velocity is 23m/s, design 4 gate 1 velocity is 21.2m/s.

When design 1 gate 3 velocity is 18m/s, and design 2 gate 3 velocity is 21m/s or design 3 gate 3 velocity is 23m/s, design 4 gate 3 velocity is 21m/s. when design 1 gate 4 velocity is 18.2m/s, and design 2 gate 4 velocity is 24m/s or design 3 gate 4 velocity is 26m/s, design 4 gate 4 velocity is 26.1m/s. So, get the all of the data and conclusion is design 3 is better than design 1, design 2, and design 4, design 3 in all gate value is higher than all gate value.

Conclusion

1) The flow velocity from the four proposed designs of gating systems, design 2 and 3 are highly varying whereas design concept 1 and 4 gives somewhat uniform flow velocity hence on the basis of flow velocity criteria design 1 and 4 comes out to be worst while 2 and 3 gives more satisfactory results. 2) Hence design concept 3 fits best in both the deciding criteria i.e. flow velocity at ingate. 3) Simulation of this modified version of design concept 3 gives better results as shown below.

References

[1] M. C. Berger, \"A theoretical basis for the design of gates,\" Foundry, pp. 112-117 and 237-242, 1951. [2] R. Ruddle, \"The running and gating of sand castings: a review of the literature,\" Institute of Metals Monograph; Institute of British Foundrymen, 1956. [3] M. Srinivasan, applied hydraulics to gating systems, The University of Birmingham, 1962.B. Sirrell, M. Holliday and J. B. Campbell, \"Benchmark testing the flow and solidification modeling of Al castings,\" The Journal of The Minerals, Metals & Materials Society, vol. 48, pp. 20-23, 1996. [4] J. Dumaillet and G. Wilson, \"Comparison of flow modification through foundry filters using both water modeling and simulation software,\" Transactions of American Foundry Society, vol. 110, pp. 1- 12, 2002. [5] F. Juretzko and D. Stefanescu, \"Comparison of mold filling simulation with high-speed video recording of real-time mold fillin,\" AFS Transactions, vol. 113, pp. 1-11, 2005. [6] M. Sutaria, \"Casting simulation case study: shaft pin (cast iron- green sand casting),\" Indian Foundry J., vol. 56, no. 12, p. 5, 2010 ASM International, “Casting Design and Performance,” 2009. [7] Berger M.J., Locke C., “A theoretical basis for the design of gates,” Foundry, 112-117 and 237-242, February 1951. [8] Bradley, F.J., Heinemann, S., “A hydraulics-based/optimization methodology for gating design”, Applied Mathematical Modeling, 17, 1038, 1993.

Copyright

Copyright © 2024 Jaydeep A Savaliya, Mitesh A Kubavat, Kankesh K Dave. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.