Journal of Production Research & Management

ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

Volume 7, Issue 3
www.stmjournals.com

Simulation and Analysis to Reduce the Shrinkage Defect

in Sand Casting for the Rotor: A Review
Hitesh Vanara1, Manojkumar V. Shalediya2
1,2
Department of Mechanical Engineering, Atmiya Institute of Technology and Science, Rajkot,
Gujarat, India

Abstract
Casting is a process in which the metal is melted and poured into mold and allows it to
solidify to get desired shape. Objective of investigation is to review on simulation and analysis
to reduce the shrinkage defect in sand casting. In ductile iron casting, shrinkage defect is
common. It is generally seen at the last solidifying area of casting. Other parameters like
getting system, feeder, metallurgy of material, part geometry, mold property also causes for
the shrinkage defect. To remove the defect new gating system is required which is developed
through analysis and with help of simulation. For that 3D CAD model is developed and
analyzed in analysis software which reduce shop flower trial and reduce material waste. The
design optimization of the casting system such as gating, choke, sprue, feeder, and riser
pouring basin can be enhanced through a series of simulations prior to physical realization of
mold and production of quality castings.

Keywords: Ductile iron, shrinkage, simulation, casting, rotor.

*Author for Correspondence E-mail: hitesh107@gmail.com

INTRODUCTION foundry worldwide. The utilization of

Shrinkage is by far the most common type and
can usually be detected on the surface of a cast
part by what appear to be small holes or
cracks. Shrinkage defects can occur when
standard feed metal is not available to
compensate for shrinkage as the thick
metal solidifies. From realistic considerations,
the experimental results are always better for
design and development of mould and for
arriving at the optimum process parameters.
However, it is expensive, tedious and might be
impossible in some cases. Therefore, casting
simulation process is a helpful method for
analyzing casting defect and other parameters
affect to casting.
There are number of casting simulation
software are developed and are used in
simulation software is increase day to day in
Indian foundry. Which reduce the shop floor
trial to accomplish the wanted inward quality
at the most noteworthy conceivable time. The
design optimization of the casting system such
as gating, choke, sprue, feeder, and riser
pouring basin can be enhanced through a
series of simulations prior to physical
realization of mold and production of quality
castings.
To analysis the casting part first step is to
make a 3D model of same dimension of part
with the help of cad software and Import cad
file into analysis software like Procast, Megma
cast, soft cast, etc. Methodology for analysis is
shown in Figure 1.

2 3 4 5
•Meshing with •Data Input •Calculation •Analysing Results
Meshcast Procast view cast

Fig. 1: Steps for Simulation.

JoPRM (2017) 23-26 © STM Journals 2017. All Rights Reserved Page 23
Simulation and Analysis to Reduce the Shrinkage Defect in Sand Casting Vanara et al.

Rathish Raghupathy and K.S.
Amirthagadeswaran have been analyzed
parametric optimization for controlling casting
defects in FG 200 multi-Stage pump adapter
components was adopted by employing DOE
and CAE tools. However, in order to
investigate on the presence of internal defects,
CAE simulation is carried out by carefully
designing the gating and feeding parameters.
They conclude that Extra allowance is to be
given for the casting design to remove this
shrinkage porosity by machining. In addition,
simulations were also carried out to find if
there is any shrinkage porosity present in the
inner sections of the pump adapter. The
optimal settings obtained through analysis and
simulations may be then applied for shop floor
trials. The shop floor trials that are conducted
validate the accuracy of the DOE and
Computer aided Engineering (CAE)
simulation software. Therefore, optimization
can be done not only on the process parameters
but also by simulating the process in a virtual
environment can be cost-effective and efficient
in producing quality cast parts [1].
Harshil Bhatt, Rakesh Barot, Kamlesh Bhatt,
have been optimize feeding system for cast
iron part. A well designed feeding system is
very important to ensure the better quality of
castings. Feeding systems are modified and
simulated unless satisfactory results are
obtained. Author attempted to modify the
existing feeding system design of component.
They stated that Foundry has problems such as
shrinkage, cold shut, mismatch and crack for
this casting. And solution for shrinkage defect
has been carried out author stated that riser
used by the company is not function well due
to that defective part is generated. Author used
cylindrical riser and location for riser have
been decided. Number of trial is performed by
the author and best suitable design is selected.
Data of trial is shown in Figure 2 [2].
They conclude that large number of trials can
be performed quickly on simulation software
package and optimum result can be obtained
which ultimately increases the profit margin of
foundry.
C.M. Choudhari, B.E. Narkhede, S.K.
Mahajan stated that the defects like shrinkage
cavity, porosity, and sink can be minimized by
designing an appropriate feeding system to
ensure directional solidification in the casting,
leading to feeders. Major parameters of a
feeding system include: feeder location, feeder
shape and size and feed aids.

Fig. 2: Data of Trial [2].

Fig. 3: Calculated Value of Design Parameter [3].

JoPRM (2017) 23-26 © STM Journals 2017. All Rights Reserved Page 24
Journal of Production Research & Management
Volume 7, Issue 3
ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)
Author stated that defect like such as
shrinkage porosity can be predict by casting
solidification simulation and corrected by
suitable modification by part design. Author
also stated at nearly 40% of casting defect is
due to the faulty design of getting system.
Proper design of feeder ensures casting free
from solidification related defects this is also
helps in improving the yield of the casting.
Data require to calculate gating system that is
given in Figure 3 [3].
Author conclude that after performing
simulation it is enable to improve and identify
the design of part within short time limit.
Proper design of gating help to achieve
directional solidification. There by solving the
problems of premature failure of junction
solidification [3].
B. Ravi stated that location of hotspot and
shrinkage defect can be predicted through
computer aided casting design and simulation.
He also state that pouring parameters and
gating system design also affect the location of
shrinkage defect The methods design involves
cores, feeders and gating system. The gating
design is driven by the ideal mold filling time,
which depends on the cast metal, casting
weight and minimum wall thickness
solidification simulation software can help in
Fig. 4: Chemical Composition [5].
Fig. 5: Relation of Temperature and Shrinkage Cavity.
JoPRM (2017) 23-26 © STM Journals 2017. All Rights Reserved
identifying the location of shrinkage defects
(porosity, centerline shrinkage, sink and pipe)
fairly accurately,; but other defects related to
solidification and subsequent cooling (such as
cracks, tears and distortion) are difficult to
predict reliably [4].
T. Kanno has investigated the effect of
pouring temperature, composition, mould
strength on the shrinkage cavity in ductile iron
casting. During experiment T. Kanno used
hypoeutectic composition to find out effect of
pouring temperature and mould strength.
Composition is shown in Figure 4.
Author investigated that during the low
pouring temperature a single mass dendritic
cavity was formed, and during high
temperature numerously spread dendritic
cavities appeared which is shown in Figure 5.
Author also stated that as near eutectic
composition volume of shrinkage cavity is
decrease where as carbon equivalent over
4.3% volume of shrinkage cavity increase. In
hypoeutectic range as carbon percent is
increase volume of shrinkage is increase. From
experiment, author suggest that increase in
nodule count prevent the formation of
shrinkage defect. Use of chill, reduce the
formation of shrinkage defect.
Page 25
Simulation and Analysis to Reduce the Shrinkage Defect in Sand Casting
B. Ravi stated that simulation is useful tool to
identify defect such as shrinkage porosity,
could shut, sand inclusion, it reduce shop floor
trial. There are number of parameters
responsible for casting defect in which major
are geometry of casting and its features like
holes, pockets, undercut, etc. along with
material and composition also responsible for
shrinkage defect. Main input for simulation is
3D cad model. Followed by design and
molding of mould, cores, feeders, gating
system. Output of simulation program is
visualization of mould filling, casting
solidification, which is lead to identify defect
such as porosity, shrinkage defect, could shut,
hot tears. It can provide batter insight than
actual trials [6].
CONCLUSION
Wrong gating design, feeder, casting
geometry, mold properties, pouring
temperature affect the shrinkage defect. To
analyze the defect like shrinkage porosity,
could shut simulation software is very useful
which reduce the shop flore trial and increase
the productivity. In casting, hot-spots are leads
to create a shrinkage porosity defect in a part
and thus reduction in hotspots reduces the
chances of shrinkage defect. Risers are placed
at last freezing region to minimize the
shrinkage defect. Changing the shape and size
of gating and feeding system reduces the
defects like shrinkage, misrun, and cold shut.
Large number of trials can be performed
quickly on simulation software package and
optimum result can be obtained which
ultimately increase the profit margin of
foundry.
JoPRM (2017) 23-26 © STM Journals 2017. All Rights Reserved
Vanara et al.
REFERENCES
1. Raghupathy R, Amirthagadeswaran KS.
Parametric optimization and solidification
analysisof grey cast pump adapter castings
using DOE and CAE. Australian Journal
of Mechanical Engineering. 2016.
2. Bhatt H, Barot R et al. Design
Optimization of Feeding System and
Solidification, Simulation for Cast Iron.
Elsevier. 2014.
3. Choudhari CM, Narkhede BE, Mahajan
SK. Casting Design and Simulation of
Cover Plate using AutoCAST-X Software
for Defect Minimization with
Experimental Validation. Elsevier,
Procedia Materials Science. 2014; 6: 786–
797p.
4. Ravi B. Computer-aided Casting Design
and Simulation. Research Gate. 2009.
5. Kanno T. Effect of pouring temperature,
composition, mould strength and metal
flow resistance on shrinkage cavities in
spheroidal graphite cast iron. International
Journal of Cast Metals Research. 2008.
6. Ravi B. Casting Simulation and
Optimisation: Benefits, Bottlenecks, and
Best Practices. Technical Paper for Indian
Foundry Journal. 2008.
Cite this Article
Hitesh Vanara, Manojkumar V. Shalediya.
Simulation and analysis to reduce the
shrinkage defect in sand casting for the
rotor: A Review. Journal of Production
Research & Management. 2017; 7(3):
23–26p.
Page 26