These actions are aimed at leading shrinkage defects to the riser, so that the casting remains free from this type of defects. Numerical simulations are then of priority importance in determining the appropriate parameters of the casting process and in selecting the shape of the riser for the casting fed with it. Making a casting without internal defects is a difficult task and usually requires numerous computer simulations and their experimental verification at the prototyping stage. Numerical evaluatioN of the impact of riser Geometry oN the shriNkaGe Defects formatioN iN the soliDifyiNG castiNG The work concerns of modeling the process of manufacturing machine parts by casting method. Validation of simulation, in the future, will be proved through experimental trials in the foundry shop. From this study, the conclusion can be stated that taper sprue design, also acts as a riser, with an additional four small risers that will produce a small fraction of porosity inside of the casting part. Casting simulation software is used for mold filling and solidification analysis and it is observed that the proposed gating and risers system design will improve casting results with small defects. ![]() It is found that defects such as micro and shrinkage porosities, and improper solidification, are directly related to gating and risers system. ![]() Only the shape and dimensional variances of sprue/risers are taken into considerations for defects analysis. Intended for simulation simplification in this study, grain size of mold green sand, casting material quality, casting process parameters are deliberated identical for all design schemes. This study, highlighting is given on using casting simulation software which helps foundry industries to design and analysis the size and shape of the riser. ![]() Computer-aided casting simulation plays an important role in the paradigm of new product development by way of modeling entire casting processes and reveals a dynamic behavior of casting scheme in working conditions. In current casting industries, product development paradigm is shifting from traditional trial-and-error in the workshop to computer-aided casting design and simulation package by a computer(s). For a large industrial application, it needs an alternate approach that is fast, reliable and user-friendly. Filling and solidification of molten metals are very complex and difficult to simulate correctly by conservative methods.
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