Metal Casting Research Articles

Use of experimental casting equipment for research of castings crystallized through individual cooling procedures

The research is devoted to development of experimental foundry pattern equipment, allowing to obtain two or more castings in a sand-loam mould; these casting are crystallized via individual cooling procedures within structurally sensitive intervals (dendrite, eutectic crystallization and recrystallization). Influence of scale factor is excluded in this case and it makes possible to obtain control and pilot castings, which have equal sizes; influence of chemical composition is excluded as well, because all castings located in a mould have common gating and feeding system. It provides the same temperature and casting speed for two or more castings in one mould with different compositions and technological properties of moulding mixtures for each of the comparing castings. Thereby, variable cooling rate, which is individual for each casting obtained in the experimental mould, remains the main factor having influence on forming of structure, mechanical and operating properties of cast metal. Possibility of investigation of rise of mechanical and operating properties of castings owing to only adjusting of cooling rate without use of alloying and modification appears in this case. Increase of the cooling rate in local temperature-time crystallization intervals is provided by blowing with cooling gases which are fed in the mould via the stand (receiver). Retarding of cooling rate occurs as a result of mould heating during thermal oxidizing destruction of exothermal carbon-containing additives which are specially introduced in the facing layer of moulding mixture. It is necessary to mention that variation of cooling rate can be conducted via the procedures which are individual for each casting located in the experimental mould. Developed and fabricated experimental foundry equipment was used for testing of the concrete cooling procedures of thin-walled castings made of grey cast iron. Pressure of cooling compressed air, which was fed during the process, and amount of exothermal carbon-containing additive, which was introduced in composition of the facing layer of moulding mixture for pilot castings were varied. As a result, the efficient cooling procedure was selected; it allowed to rise tensile strength for the pilot casting by 13 %, to improve cast iron quality (quality index) by 23 % and to increase structure dispersity of primary austenite by 21 % without introduction of alloying elements and modifiers in cast iron composition.

Mechanical Characterization and Numerical Optimization of Aluminum Matrix Hybrid Composite

Hybridization of aluminium matrix composite is with a view to offset the properties deficient in one composite reinforcement. The present investigation involves a comparative study of AA6063 matrix composites with single reinforcement of Al2O3, SiC, graphene respectively and various hybridized proportions of the same reinforcements. Physical (density and %porosity) and mechanical (tensile strength, fracture toughness, %elongation, elastic modulus, etc.) properties of composites developed via solidification processing technique were evaluated. The porosity of all the composites falls below the maximum acceptable limit for cast metal matrix composite. Maximum values for UTS, %elongation and absorbed energy at maximum stress was obtained by hybrid composite with 4wt% Al2O3, SiC and 2wt% graphene, while the composite with the highest single reinforcement of graphene have the highest value for elastic modulus and fracture toughness. Numerical optimization results show that a matrix and hybrid reinforcements contents of AA6063 (91.413wt.%), SiC (3.679wt.%), Al2O3 (0.277wt.%), and graphene (4.632wt.%) respectively, will result in optimal values for the evaluated properties.

Composition of non-metallic inclusions and microstructure of electric arc coating formed using the flux-cored wire of Fe – C – Si – Mn – Сr – Ni – Mo system

The article considers the study of composition of the non-metallic inclusions and microstructure of the electric arc coating using the flux-cored wire of Fe – C – Si – Mn – Cr – Ni – Mo system. Formation of the electric arc coating was carried out using the ASAW-1250 automatic arc welding machine by the investigated wire. In order to influence the level of contamination of the deposited metal with non-metallic oxide inclusions, aluminum gas purification dust was introduced into the flux-cored wire (instead of amorphous carbon). Composition of the electric arc coating was determined using XRF-1800 spectrometer. Microstructure of the electric arc coatings was studied by optical microscopy. The phase and elemental compositions were studied using scanning electron microscopy on MIRA 3 LMH instrument. Non-metallic inclusions in the electric arc coating consist of oxides of silicon, fluorine, calcium, aluminum and magnesium oxides. The darker component in the inclusion, which looks like rectilinear crystals directed from the surface deep into the inclusion, has a similar phase composition, but differs somewhat in the content of chemical elements. A small dark component of a rounded shape (aluminum and magnesium oxides) is observed in the inclusion. Traces of sulfur are highlighted along the contour of the globules. Metallographic analysis of the deposited surface showed that the microstructure of the deposited layer is a coarse-needle martensite. The structure is uniform, has a dendritic (columnar) structure characteristic for cast metal. The results of the conducted investigations allow measures to be developed to reduce the content of non-metallic inclusions containing elements of fluorine, sodium and aluminum, which in turn may adversely affect the physical and mechanical properties of the deposited layer, for example, by using refining additives to reduce the contamination of the deposited layer with non-metallic inclusions.

Deep purification of tellurium, zinc and cadmium for use in electronic devices

A combined method of profound purification of Cd, Zn and Te developed by the Authors and allowing one to produce high-purity materials in a vertical reactor unit has been considered. The method includes the following processes: filtration refinement of metal alloy with the possibility of its vacuum degassing and additional purification through an oxide layer; first distillation with the possibility to use gettering additions in the melt and gettering filters; melt degassing with the removal of highly volatile impurities to the condenser in rough vacuum; second distillation and metal casting for weighed quantities. The Authors have developed and produced a test model of the unit for the experimental profound purification of metals using the method developed herein. Physical experiments have been conducted for obtaining 99,9999 wt.% purity Cd, Zn and Te for 30 residual impurities with a product yield of at least 55%.

Retention protocol following post-orthodontic treatment in cleft palate patients – A review

To evaluate and compare the available literature on efficiency of different retention appliances in maintaining the results achieved after orthodontic treatment in cleft palate patients. On comparing the literature available on different retention appliances currently available, it was found that the cast metal retainers offered a more stable and rigid design to maintain the post treatment arch width and also provided the aesthetic replacement of the missing teeth in the cleft region by incorporating a pontic. The cleft lip and palate patients should be informed and motivated for a long term or indefinite retention phase irrespective of the type of retention appliance used. Presently, very few studies are available comparing the effectiveness of different retention protocols in cleft lip and palate patients. Hence, there is need to conduct evidence based high quality longitudinal studies to compare the effectiveness of different retention appliances.

Application of Rapid Prototyping in Prosthodontics

Purpose: Rapid Prototyping (RP) methods have for quite some time been utilized to construct complex 3-Dimensional (3D) models in the field of medicine since the 1900s. This paper intends to offer a thorough audit of different RP strategies, especially in Prosthodontics that are relied upon to carry numerous enhancements to this field. Materials and Methods: A pursuit was made using the Google scholar web and the PubMed database as a search engine. The keywords; ‘RP’, ‘rapid prototyping’, ‘3D printing’, ‘dentistry’ and ‘prosthodontics’, ‘stereolithography’, ‘selective laser sintering’, ‘fused deposition method’, and ‘inkjet-based system’ were looked at in the title/abstract of distributions. References of selected articles were additionally looked into for conceivable incorporation in the study. The selected articles utilized RP procedures in different fields of dentistry through various methods. Nonetheless, distributions concerning the dental utilization of RP advancements are as yet uncommon. Results: Although the concept of layering 3D objects is almost as old as human civilization, this technology has only lately been applied to the construction of 3D complex models in dentistry. Many additional methods appear to be on the horizon that could alter standard dentistry practises in the near future. More unit hours should be included in dentistry curriculums to familiarise dental professionals with the various advantages of this unique technology. Conclusion: Lately, RP using the property of adding substances or layering strategies have advanced quickly in different fields of dentistry as they can overcome known disadvantages of subtractive and regular procedures. RP has as of late proposed effective uses in different fields of dentistry, like fabrication of implant surgical guides, structures for Removable Partial Dentures (RPDs), Fixed Partial Dentures (FPDs), wax designs for the dental prosthesis, maxillofacial prosthesis, zirconia prosthesis, and molds for metal castings now as well for complete dentures.

Profound purification of tellurium, zinc and cadmium for electronic applications

A combined method of profound purification of Cd, Zn and Te developed by the Authors and allowing one to produce high-purity materials in a vertical reactor unit has been considered. The method includes the following processes: filtration refinement of metal alloy with the possibility of its vacuum degassing and additional purification through an oxide layer; first distillation with the possibility to use gettering additions in the melt and gettering filters; melt degassing with the removal of highly volatile impurities to the condenser in rough vacuum; second distillation and metal casting for weighed quantities. The Authors have developed and produced a test model of the unit for the experimental profound purification of metals using the method developed herein. Physical experiments have been conducted for obtaining 99,9999 wt.% purity Cd, Zn and Te for 30 residual impurities with a product yield of at least 55%.

Solidification simulation of single-phase Fe–Co–Cr–Ni–V high entropy alloy

ABSTRACT For the first time, we report here the heat transfer and solidification behaviour of Fe–Co–Cr–Ni–V single-phase face centred cubic (FCC) high entropy alloy (HEA) by adopting synergistic approach involving numerical simulation and experimental techniques. The present study explores the analysis of the solidification behaviour, temperature distribution within the metal casting as well as metal casting to the mould through metal casting–mould interface and phase change during solidification. The experimental measured hardness of studied HEA which varies from 236 ± 5 HV to 272 ± 4 HV at particular 500 g load is correlated with the simulated cooling curves. Electron Backscatter Diffraction analysis reveals that the average grain size is approximately 214.3 μm. The simulated results are in good agreement with the experimental findings. Furthermore, a comparison of the cooling curves of studied HEA obtained by two simulation techniques is established.

ЗАСТОСУВАННЯ МЕТОДУ АРМУВАННЯ ПІНОПОЛІСТИРОЛЬНИХ МОДЕЛЕЙ ДО 3D-ДРУКУ СТІН З ПОЛІСТИРОЛБЕТОНУ ТА ПРИКЛАДИ МЕТАЛЕВИХ ЛИТИХ ДЕТАЛЕЙ БУДІВЕЛЬНОЇ ОПАЛУБКИ

An urgent need is to increase the productivity of the construction of both residential buildings and office buildings. One of the driving directions of modern building science is the desire to combine different properties in one material. Science made cold and heavy, but strong concrete light and “warm” by introducing foamed balls-granules of polystyrene polymer into the structure, and this created polystyrene concrete (PSB). Despite the sufficiently high strength for low-rise construction, PSB blocks are quite fragile. In order to avoid cracks in the walls and destruction under the floor panels, they need a monolithic reinforced concrete belt, the manufacture of which leads to unnecessary costs of materials and time. To automate the construction of PSB, methods of 3D printing of walls directly at the construction site are known. Such a new method is considered with polystyrene foaming directly in the current PSB layer by passing an electric current through this PSB layer, which heats this layer, which leads to foaming of polymer granules and acceleration of PSB hardening. This method has been improved by us with a technical solution for reinforcing joints between layers with their additive build-up. This will increase the strength of building structures, and will similarly allow the laying of cables, corrugated sleeves or tubes for electrical wiring or communications in the walls. For the manufacture of metal-reinforced monolithic concrete belts in walls made of PSB under floor panels, partitions, blocks, slabs or panels for flooring, formwork is used, the metal parts of the fasteners of which are debugged to be mass-produced by casting. At the same time, steel nuts for formwork ties, as well as key parts of building frame scaffolding according to the FTIMS NAS of Ukraine technology, are cast on gasified models, as a rule, with cast threads from M16 and larger, which does not require their machining. This is illustrated by examples of cast metal fasteners.

Determination of Casting Parameters for Affirmative Directional Solidification in 750 KW Francis Runner

Entangled by a web-like pattern of rivers and rivulets, Nepal’s energy sector currently is dominated by hydroelectricity which sustains a major portion of the country’s economy. But still, after more than a hundred years of its operation, the sector’s dependence on imports is uncanny. This not only upsizes the project cost but also the time and human resources. The research, therefore, aims to aid the cause by examining the prospect of manufacturing runners using local industrial expertise in synchronization with available data and research. Here, the paper focuses on the sand casting of a 750KW Francis runner and the design of its parameters namely gating and feeding system to ensure directional solidification. Apart from the conventional procedure, the casting of the runner was proceeded as three separate parts: hub, shroud, and blade which were later welded together. The gate and riser placement for each of the parts was designed independently and analysed for any shrinkage porosities and possible voids using computer simulation with several iterations each. Specifically, temperature variations during three major stages of solidification assigned as 0, 50, and 100 were tested for a total of 195 nodes. The design was then transferred into the mould and casting was performed. The procedure resulted in a cast with a clean surface finish and minimal visible defects. The study, thus, suggests the possibility of manufacturing runners through metal casting and its substantial implications in the improvement of the hydropower industry in Nepal.

CAD-CAM denture teeth made on cast metal removable partial denture frameworks

Once the fit of the cast metal framework on a removable partial denture (RPD) has been verified, the manufacturer’s prefabricated denture teeth are typically secured on the cast metal framework to prepare for a wax evaluation. Although prefabricated denture teeth are available in different tooth forms and sizes, they require modification to fit an edentulous space. In arches with severe space discrepancy, it may be inefficient and time-consuming to make modifications to prefabricated denture teeth. The technique described uses digital technology to fabricate custom denture teeth on a cast metal framework and establish harmonious occlusion. An edentulous space with more than a single tooth replacement is designed as a splinted fixed partial denture with a connector. The designed teeth are milled in the double-cross-linked polymer to prepare for a wax evaluation, and once verified, the RPD is processed by using heat polymerization. Modifications are made to the milled denture teeth after wax elimination to reduce the likelihood of acrylic resin bond failure.

An a Priori Discussion of the Fill Front Stability in Semisolid Casting

Metal casting is an industrially important manufacturing process offering a superior combination of design flexibility, productivity and cost-effectiveness, but has limitations due to filling related defects. Several semisolid casting processes are available capable of casting at a range of solid fractions to overcome this. The current communication aims to review the filling front behaviour and give a new perspective to the gate design in semisolid processing compared to conventional high-pressure die-casting. It is shown that solid fraction and gate widths are critical to avoid instability and spraying.

Mathematical Simulation of Heat Transfer in Thermally Magnetised Oldroyd-B Fluid in Sakiadis Rheology with a Heat Reservoir

Sakiadis rheology of a generalised polymeric material, as well as a heat source or sink and a magnetic field, are all part of this study. Thermal radiations have been introduced into the convective heating process. The translation of a physical situation into a set of nonlinear equations was achieved through mathematical modelling. To convert the resulting partial differential equation into a set of nonlinear ordinary differential equations, appropriate transformations have been used. The velocity and temperature profiles are generated both analytically by HAM and numerically by the Runge–Kutta method (RK-4). In order to analyse the behaviour of the physical quantities involved, numerical and graphical depictions have been offered. To show that the acquired findings are correct, a nonlinear system error analysis has been offered. The heat flux study has been shown using bar charts. For the essential factors involved, the local Nusselt number and local Skin friction are calculated in tabular form. The fluid particles’ molecular mobility was slowed due to the magnetic field and porosity, and the heat transfer rates were demonstrated to be lowered when magnetic and porosity effects are present. This magnetic field and porosity effects regulating property has applications in MHD ion propulsion and power production, the electromagnetic casting of metals, etc. Furthermore, internal heat absorption and generation have diametrically opposed impacts on fluid temperature. The novelty of the present study is that no one has investigated the Sakiadis flow of thermal convection magnetised Oldroyd-B fluid in terms of a heat reservoir across a porous sheet. In limited circumstances, a satisfactory match is revealed when the collected values are compared to the existing work published corroborating the current attempt. The findings of this study are expected to be applicable to a wide range of technical and industrial processes, including steel extrusion, wire protective layers, fiber rolling, fabrication, polythene stuff such as broadsheet, fiber, and stainless steel sheets, and even the process of depositing a thin layer where the sheet is squeezed.

Fit of removable partial denture frameworks fabricated from 3D printed patterns versus the conventional method: An in vitro comparison

Statement of problemThe conventional method of fabricating removable partial denture (RPD) patterns is a time-consuming, expensive, and complex process, and the success of the treatment depends on the fit of the framework. Questions still remain as to whether the 3D-printing method is an acceptable procedure compared with the conventional method. PurposeThe purpose of this in vitro study was to compare the fit of RPDs cast from 3D printed frameworks and conventionally fabricated RPDs according to the gaps between the framework and the reference model. Material and methodsA metal reference model was made from a Kennedy class III modification 1 maxillary typodont. For the conventional group (n=9), impressions were made from the metal cast. Cobalt chromium frameworks were cast with the conventional method. For the digital group (n=9), the metal cast was scanned with a laboratory scanner, and the RPD was designed in the 3Shape platform. The standard tessellation language (STL) file of the design was downloaded to a 3D printer (Hunter DLP), and 9 resin frameworks were printed. These frameworks were invested and cast in the same dental laboratory as the first group. Gap measurement was assessed vertically with a superimposition software program (Geomagic Control X), and additional measurements were assessed under rests, reciprocal arms, and a 2.2-mm box under the major connector. The independent t test was used for determining the results and statistical analysis between groups. The paired t test was used for statistical analysis within groups (α=.05 for all tests). ResultsNo significant differences (P>.05) were observed in the mean ±standard deviation in overall fit according to the gaps in the conventional group (103 ±18 μm) and those in the digital group (109 ±21 μm). The biggest gap (poorest fit) was observed in the 2.2-mm box under the major connector (115 ±6 μm). ConclusionsBoth conventional and 3D-printing methods showed clinically acceptable fits. Further clinical studies with a larger sample size and long-term follow-up are needed.

Pengenalan Aplikasi Pengecoran Logam Berbahan Dasar Sampah Kemasan Kaleng Untuk Pembuatan Produk Wajan Bagi Masyarakat Kota Kendari

One of the classic problems that are difficult to overcome in urban life is environmental problems where waste is not handled properly, especially inorganic waste. Currently, the largest contributor to waste after organic waste is inorganic waste in the form of canned waste. The use of aluminum as a packaging material is due to its being lightweight, easy to shape, and does not endanger human health. On that basis, its use as packaging is widespread which also triggers the forerunner of the waste problem in people's lives. Aluminum waste will be a source of income for the community if it is handled properly by involving waste processing technology in the form of recycling technology through metal smelting or casting. This service program aims to introduce metal casting applications made from canned waste into frying pan products for the community in Lepo-Lepo, Kendari City. The activity stages include: socializing the introduction of aluminum-based cans of packaging waste and the practice of smelting aluminum cans in a crucible furnace and pouring molten metal into molds. The implementation of this service activity can raise awareness of participants to be able to process waste, especially aluminum can packaging into frying pan products, and create new jobs to improve the welfare of the local community.

A simplified technique for fabrication of obturator using light curing wax pattern: A case report

Surgical excision of the maxilla results in communication between the oral cavity, nasal cavity and maxillary sinus. Rehabilitation of such defects involves fabrication of obturator prosthesis by the maxillofacial prosthodontist. Various techniques and materials have been used in the past for rehabilitation of such defects.To Fabricate a Obturator Prosthesis using Light Cure Wax Pattern.A 65-year-old man reported with the chief complaint of inability to chew food due to an ill-fitting prosthesis. His history revealed that patient had undergone maxillectomy of left side due to Carcinoma maxilla 03 years back, followed by the fabrication of a definitive obturator prosthesis. Intraoral examination revealed a well healed Aramany’s Class II post maxillectomy defect on the left side measuring 5 cm X 3.5 cm anteroposteriorly and mediolaterally, with everted margins and irregular borders. This clinical report describes rehabilitation of maxillectomy defect with definitive obturator prosthesis. A light cure wax pattern was used (LiWa®; Willmann & Pein Gmbh) for the fabrication of metal framework.Fabrication of a cast metal framework involves a complex laboratory procedure to achieve the clinical success of the prosthesis. LiWa light curing waxes can be successfully used as an alternative to the conventional wax pattern for the fabrication of cast partial dentures framework for definitive obturators.The light cure wax pattern helped in reducing the number of laboratory steps and allowed wax pattern trial in the patient's mouth, saving precious time and ensuring a precise fit of the prosthesis.

Clinical approaches and removal of cast metallic posts for their replacement by the fiberglass posts: a concise systematic review

Introduction: A successful placement of an intraradicular post needs a good endodontic treatment. Consideration should also be given to the possibility of its future removal. Authors have shown that approximately 10% of cases of teeth indicated for endodontic retreatment require removal of intraradicular posts. Objective: To carry out a concise systematic review to analyze the reasons for replacing intraradicular posts, the most effective and used techniques for removing the metallic post, the manufacture of the fiberglass post, and the difference between the two types of posts. Methods: The present study followed a systematic review model, following the rules of systematic review – PRISMA. The search strategy was performed in the PubMed, Cochrane Library, Web of Science and Scopus, and Google Scholar databases. Results and Conclusion: A total of 112 articles were found. A total of 56 articles were fully evaluated and 18 were included in this study. Based on the objective and results found in the present study, the review demonstrated the main advantages and disadvantages of the clinical performance of cast metal posts and fiberglass posts, as well as the reason for switching from metal to fiberglass posts. Despite the wear caused by endodontic treatment, it is important to check the remaining dentin to choose the best retainer, observing the amount of this remaining structure, as it directly influences the selection of the post. Regarding the removal of the metallic pin, wear, ultrasound, and seizure/removal with some traction device are used. The replacement of the metallic post can opt for fiberglass posts because they have a greater advantage compared to the metallic post, mainly for aesthetics, the manufacturing technique is more agile, they do not generate risks of root fracture and if, for any eventuality, it needs to be removed. to portray the channel, the technique is smooth and easy.

Modeling and Optimization of Properties of the Environmentally Clean Molds Based on Oligofurfuryloxysiloxanes for the Production the Metal Castings.

This article is devoted to modeling, researching and optimizing the main properties of an environmentally clean polymer composition based on oligofurfuryloxysiloxanes (OFOS), which can be used to produce casting molds and cores in the production of castings from ferrous and nonferrous metals. Polymer compositions were examined for strength, survivability, gas permeability, moisture, crumbliness, fire resistance, knockout, and stickability. It has been established that the increase in the strength of the polymer composition over time obeys an exponential law. Mathematical equations were derived for all the exponential curves. The indications of compressive strength of the polymer composition with OFOS with all the acid catalysts used were, on average, as follows: after 1 h—1.3–1.54 MPa; after 3 h—2.5–2.9 MPa; after 24 h—4.9–6.1 MPa, which meets the requirements for casting molds before pouring with metal. The use of polymer compositions with OFOS ensures environmental safety of the technological process, due to the lack of emission of toxic substances, both in the “cold” stage of the process and during casting with molten metal, cooling, knocking out, and disposal of polymer compositions. This makes it possible to save energy resources, and thereby reduce the total cost of the entire technological process and castings.

The Effects of a Vertical Compressive Cyclic Load on Abutment Screws and the Stability of the Prosthesis in Nonengaging and Partially Engaging Abutments in a Screw-Retained Splinted Fixed Dental Prosthesis.

To evaluate the effects of vertical compressive cyclic load on abutment screws and the stability of screw-retained splinted fixed dental prostheses supported by bone-level nonengaging and partially engaging abutments. Ten standardized two-unit prostheses integrated with nonengaging and partially engaging abutments were 3D-printed and cast in nonprecious metal and attached to two implant analogs with conical connections angled 15 degrees toward the vertical axis in a resin bock. The common path of insertion for the prosthesis with partially engaging abutments to angled implant analogs was created by selectively reducing the abutment surface that obstructed the implant housing. A 500-N average load was applied to each sample while oscillating 30 degrees from the vertical axis at 60 Hz to failure. Prosthesis stability was measured by deflection from the initial position using a linear displacement measuring device. Sample groups were assessed using the independent-samples t test and one-way repeated-measures analysis of variance (ANOVA) with post hoc tests. The mean cycles to failure for nonengaging and partially engaging abutment groups were 27,180 ± 29,420 and 457,890 ± 265,734, respectively. Failed nonengaging samples had 9 out of 10 abutment screws fracture inside the implant housing but with minimal wear to the top of the implant analog. For partially engaging samples, 8 out of 10 implant housings and 7 out of 10 abutment screws fractured at test endpoints. There was no difference in initial deflections between groups. Prostheses supported by nonengaging abutments failed before deflection measurements could be taken after loading. Prosthesis displacement of partially engaged abutments decreased significantly from the initial position after 300,000 load cycles. Under the experimental conditions, screw-retained splinted fixed dental prostheses supported by partially engaging abutments are 17 times more stable than prostheses supported by nonengaging abutments. Abutment screw fractures are the most prevalent mode of failure for nonengaging abutments at significantly lower cycles with minimal wear on implant analogs. Partially engaging abutment groups failed from implant housing and abutment screw fractures at higher cycles. Loading appears to concentrate preferentially on the medial side on all angled implant components. Selective removal of the abutment obstruction allows a common path of insertion for multiple implants and partial engagement to implant housings.

Optimization of Gating System for Sand Casting Using Sequential Quadratic Programming

Abstract: Lower rate of filling of metal in sand casting is a common and avoidable problem in the production unit. This often leads to increase in expenses as well as time taken. By optimizing the gating system design, we can reduce the inferiority in the products and hence reduce the cost and time taken