DESIGN AND ANALYSIS OF THE GATING AND RISERING SYSTEM FOR STEEL SAND CASTING

Abstract

Steel sand casting involves complex processes that significantly impact the quality and integrity of the final product. Among these processes, the design of the gating and risering systems plays a crucial role in ensuring defect-free castings. This research focuses on optimizing the gating and risering system design for steel sand casting with the aim of improving casting quality and minimizing defects. Through a detailed case study, the study seeks to develop a robust gating and risering system specifically tailored for steel casting applications. Computational applications using CATIA software for 3D modelling and Altair Inspire Cast for process simulation and analysis was employed to rigorously evaluate and validate the effectiveness of the proposed design. The study aims to meet performance criteria and enhance casting integrity. The ultimate goal is to propose an optimal gating and risering system configuration that not only addresses the challenges identified in the case study but also serves as a practical guideline for improving the overall efficiency and quality of steel casting processes. Key findings from the study highlight velocity, solid fraction, and porosity as significant parameters during the filling and solidification process, providing benchmarks for improving the casting process. Ultimately, an improved model with a yield improvement of 17.65% and an enhanced casting process was achieved. The findings underscore the importance of an optimized gating and risering system in enhancing the casting process, reducing defects, and producing high-quality steel products through detailed filling and solidification analysis, ultimately improving casting yield.