Simulation and experimental analysis of re-design the faulty position of the riser to minimize shrinkage porosity defect in sand cast sprocket gear

Abstract

Shrinkage porosity is known to occur when feeding is cut off due to several reasons that can cause an early solidification of the molten metal on the riser affecting the overall feeding process. Casting simulations can give a clear understanding of determining the existence of shrinkage porosity by considering variable process parameters like the improper design of a riser and faulty positioning of the riser. This research work aims to investigate and minimize the occurrence of the open shrinkage porosity resting on a sprocket gear made of Carbon steel Material. The design of the gating system was done using Modulus Methods, and 3D Model was prepared by using CATIA software. The optimization of the feeding and gating system is conducted using PROCAST software, taking into account the actual casting data from the foundry and the experiment was conducted to validate the simulation results. The analysis of PROCAST predicts that the position and feed volume of riser is the key factor for sound casting by showing porosity concentration is less and casting experimental result validates the increase weight final casting than earlier. An improvement in the overall quality of the product was observed when compared to sprocket gears produced in the foundry before.