Abstract
Casting is a manufacturing process for making complex types of metal materials. Sand casting is one of the widely used casting processes due to its inherent advantage of no size and shape constraint with low costs. The main problem with sand casting is defect and yield. Optimization of process parameters and gating system design can solve these problems.The configuration of the gating or riser mechanism plays a very significant role in enhancing casting efficiency.Several researchers reported that 90 percent of casting defects are only obtained due to improper gating and feeding system design.Simulation can help in this matter a lot to optimize the various process parameters to get sound casting. In the present work, the behavior of metal filling and solidification was examined using AUTOCAST – X1 casting simulation software and flowplus module. Aluminum alloy AlSi5Cu3 was selected due to its excellent properties and a wide range of commercial applications in automobile and aerospace. The sand mold is selected as mold material and defect identification has been carried out and confirmed by comparing the simulation results with the experimental one.
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