Casting Design and Simulation of Cover Plate Using AutoCAST-X Software for Defect Minimization with Experimental Validation

The process of casting solidification is complex in nature and the simulation of such process is required in industry before it is actually undertaken. The defects like shrinkage cavity, porosity, and sink can be minimized by designing an appropriate feeding system to ensure directional solidification in the casting, leading to feeders. Major parameters of a feeding system include: feeder location, feeder shape and size and feed aids. In this study, the component suffered from shrinkage porosity defect leading to premature failure. It also was subjected to incomplete fill due to sudden variation in thickness. Hence, it was necessary to redesign and redevelop the component. Component geometry has been modified without affecting its functionality by providing sufficient draft and radius at the junction. In this paper, an attempt has been made to carry out the entire methoding, simulation and optimization in AutoCAST X software which is based on Vector Gradient Method (VGM). All the design parameters have been set properly in numerical simulation software so that entire shrinkage porosity should get shifted in the feeder. This attempt has shown significant improvement in the quality of casting by optimizing the location and design of feeder for defect minimization. The simulation results were found to be in good agreement, when compared with the experimental trial.