Minimization of Gas Porosity Through Casting Simulation Tool for Sand Casting

Porosity is the one of the defects most frequently encountered in ductile iron casting. Porosity formation cause costly scrap loss and limits the use of cast parts in critical high strength applications. The amount of porosity is closely related to sand casting processes parameters. A considerable reduction in porosity formation can be obtained using optimization technique in the sand casting process. Casting is a manufacturing process to make complex shapes of metal materials in mass production may experience many different defects such as gas porosity, pin holes, blow holes, shrinkages and incomplete filling. The Gating/riser system design play very important role for improving casting quality. Due to the lack of scientific procedures the design process is normally carried on a trial-and-error basis. The main objective of this paper is to redesign the components using Auto-CAST X1 simulation software and increases the product life. Many researchers reported that 90% of the defects in casting are obtained only because of wrong design of gating and feeding system and only 10% due to manufacturing problems. In this paper to study the solidification behavior of material, detection of hot spots, blow holes and removed such defects in the casting with the help of mentioned casting simulation software. The simulated results also compared with experimental results.