Abstract
Casting of metal products consists of a series of intricate manufacturing processes that need to be precisely conducted and controlled. Rather than doing process design by a hit-and-trial approach, simulations can be run before casting is actually undertaken in a foundry. These simulations allow to model, verify, and validate the entire casting process along with the prediction of possible defects in the cast products. This study is based on casting an adjuster bracket using traditional mold design approach, and also using simulation. A Computer-Aided Design (CAD) model of the casting is developed in SOLIDWORKS and simulated using MAGMASoft. The results obtained are temperature profile within the mold after pouring, solidification sequence, and casting defects such as porosity and hotspots. Good correlation between experimental and simulation results confirmed sufficient model health to virtually optimize the mold through simulations. The optimized mold design completely removed the hotspot and reduced porosity which is within the machining allowance of the final product. However, the casting yield is reduced by 6% by adding a carefully selected riser in the optimized mold design. It can be concluded that simulations are reasonably accurate in modeling casting process, predicting defects, and modifying casting design using optimization techniques available in the advanced casting simulation software.