e-ISSN: 2456-3463

International Journal of Innovations in Engineering and Science, Vol. 2, No.5, 2017

www.ijies.net

A Review on Investigation of Casting Defects

with Simulation
Akash A. Gaware, Dr. A. K. Mahalle
Student, M. Tech CAD/CAM, GHRCE Nagpur, India,
Professor, Department of Mechanical Engineering, GHRCE Nagpur, India,
E-mail: [email protected]

Ab st ra c t: Aim of this paper is to investigate casting Filling molten metal into molding box
defects, provide remedies and simulation of casting Allowing molten metal to solidify.
process by using casting simulation software. Casting Removal of solidified object from the mold and
defect occurs where mistake happens in the process of carry on further treatment.
casting. Most defects occur due to improper feeding
system. Simulation is helpful in minimizing the casting Ca st i ng ter ms
defects. Various simulation softwares like AutoCAST-X,
ProCast & SOLIDCast can be used. Flask: A flask holds the molten iron intact.
Cope: Upper flask.
Ke ywo rd s: Casting, casting defects, remedies, Drag: Subordinate flask.
simulation
Pattern: It is the alter ego of desired product.
Allowance: To compensate various defects, extra
IN T RO D UC T IO N
dimension is provided as allowance.
Sand Casting: Cheek: Middle flask.
Core: Unoccupied spacing produced in casting if
required.
Casting is a process of making solid objects by pouring Pouring Basin: Small semicircular hole at top for
molten metal into a cavity of required shape and allowing filling molten metal
it to solidify. The solidified product is called casting. Sprue: Pathway for molten metal to reach cavity
from pouring basin

Fig 1: Casting

Casting involves following steps:

Fig 2: Schematic illustration of sand molding
Melting the raw metal.

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 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol. 2, No.5, 2017
www.ijies.net

Runner: Molten iron is filled in runner to reach Causes:

cavity. Non uniform solidification
Gate: Door of cavity Pouring temperature
Chaplet: Used for backing cores and to overcome Extreme release of gas
metallostic forces. Remedies:
Chill: Metallic chills used for desired cooling Location of riser should be proper
rate. Proper position and using chills for better
Riser: It is filled when cavity is completely full of solidification
liquid metal. It also helps to flow metal Providing good venting.
backwards.
b) Blowhole defect:
Probability of accomplishing defect free manufacturing It is fairly large, rounded cavity formed due to gases
practice is very less. Most of the metallic parts are inside the molten metal.
manufactured by casting process. Casting defects occurs
due to some errors in casting process. Defects reduces the
superiorityof product, eventually it becomes unacceptable.
It is essential to investigate the casting defects for
improvement; also finding causes of defects is significant.
Casting inspection approaches are basically classified as
destructive and non-destructive tests (NDT). Casting may
be damaged in destructive test during strength test. NDT
test does not damage the part. Some tests are visual test,
dimensional test, pressure test, sound test, radioscopic Fig 4: Blowhole defect
inspection, magnetic particle test, liquid penetrant test, Causes:
impact test, etc. Entrapment of gases
Well-designed feeding system reduces the casting defects Low permeability
drastically. Quality of product relies on the quantity of Moisture absorbed by cores
risers and location of runners and risers. Making changes Rusted chills, chaplets
in the feeding system and relocating the positions of risers Remedies:
manually is time taking hence simulation can become an Use of dry chills
important gizmo to improve the feeding system which will Provide adequate venting
help to develop quality product. Alteration in gating arrangement
Ca st i ng d ef ec t s
c) Misrun:
a) Shrinkage defect:
This defect occurs due to lack of design and Unfilled portion of the cavity is known as misrun. It
insufficient feed metal. Shrinkage can be a void in the arises when molten metal doesnt fill the cavity
casting. completely.

Fig 3: Shrinkage defect Fig 5: Misrun

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 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol. 2, No.5, 2017
www.ijies.net

Causes: Carelessness during the placing of upper and

Poor flow ability lower boxes
Poor feeding and gating system
Remedies: Remedies:
Proper speed of filling process Rectification of correct dowels
Modification of design Using proper molding and pins

d) Cold shut: f) Cracks:

A cold shut is a crossing point within a casting which is This defect occurs due to number of reasons. Some cracks
produced when two metal streams do not fused together. visible by naked eye and too small cracks need to magnify
Void having round edges is also a sign of cold shut. for observation.

Fig 6: Cold shut

Causes: Fig 8: Crack

Too cold molten metal Causes:
Thin casting sections Thermal disparity in the die
Poor fluidity of molten metal Internal stresses
Remedies: Damage in cavities
Modify design and feeding system Remedies:
Proper temperature needed. Avoid superheating
Use of chills
e) Mismatch defect:
Proper composition
It occurs because of fluctuation of molding flashes. It
g) Sand inclusion:
causes dislocation of parting line.
It is also known as sand hole. It is the sand remained in the
casting after solidification.

Fig 7: Mismatch defect Fig 9: Sand inclusion

Causes: Causes:
Improper position of cope and drag Irregular compaction of mold
Low compact ability
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International Journal of Innovations in Engineering and Science, Vol. 2, No.5, 2017
www.ijies.net

Too high pouring rate emedies: L I T ER AT U RE R E VI E W

Strength of core should be increased
This includes brief information about the work done by
Dodge core mismatching
various authors in reducing the casting defects and
enhancing the quality of product. Author has worked on
Si mu la t io n
examination of irregularity in casting and remedies are
provided to get zero defect casting. Study reveals that
Casting simulation enables envision of whole casting
rejected casting include sand drop, blowhole, and
process. Simulation helps to see the differences made to
mismatch defects. These defects were frequently occurring
the product and helps to take decision which will lead to
in the casting. Analysis provides remedies to overcome
technically sound product.
casting defects. Validation of trials reduces most of the
Simulation finds the defected area like shrinkage,
defects. [1] In this review several casting defects and their
blowhole, cracks etc. It is used for improving the existing
occurrence cause were identified. Study is helpful in
casting and also for manufacturing newly design casting
examining the defects and application of remedies. Casting
within very less time. Simulation primarily helps to
defects should be less to avoid rejection. One can
improve the superiority of product and its faster growth.
continuously control rejections by taking in to
Simulation requires very less input data and gives reliable
consideration different parameters at every stage of
results which have impact on quality and yield. Separate
production. Thus it is indispensable for a foundry expert to
design software is necessary to make CAD model as an
have awareness on the identification of type of defect and
input to simulation software. Simulation softwares
to identify the exact root cause, and their remedies. Hence
accessible in India like ProCast, SolidCast, AutoCAST-X
this systematic work will be fruitful for quality casting
and MAGMA.
manufacturing. [2] Author has worked on finding defects
in casting process.The full picture for existence of
contraction defects is provided and solution is provided.
By appropriate casting method developing feeding system,
appropriate position of ingates and feeders will lessens the
contraction defect. Softcast software is recommended for
simulation of casting. [3] Author provides an intense
knowledge of critical defects and their root cause analysis.
This paper emphasizes on technically viable solutions for
decreasing several defects and enhancing the superiority of
castings which will be guidelines for foundry engineers.
[4] Surface analysis of discontinuities produced in castings
is effective for evaluation of castings irregularities and
implementing preventive measures. [5] Agenda of work is
to probe the probable sources of gases like nitrogen,
hydrogen and oxygen, concentrating on making practice
Fig 10: Simulation
that is in contact with the liquid steel. Disadvantages of
chemical and gas content are examined. Also gas removing
It includes following steps: capability of casting should be increase. [6] Study of
Data gathering influencing factors for blowholes in die casting is essential.
Part modeling Aluminum Parts of compressor are studied. Various
Gating system design factors like pressure, pouring speed, starting position and
Simulation void pressure are examined. Paper focus is on blowhole
Optimization reduction by considering venting system also. [7]
Report generation Special systems are used for processes that are influenced
by multiple events to take decisions. Special systems are

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 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol. 2, No.5, 2017
www.ijies.net

innovated on fuzzy method to detect the incidence of RE F ER E NC E S

foremost casting defects. Study concentrates on sand
casting of gray iron. Developed systems help the foundry 1. Dr. D.N. Shivappa, Mr. Rohit, Mr. Abhijit Bhattacharya,
engineers to take decisions regarding sand casting to avoid Analysis of Casting Defects and Identification of Remedial
Measures-A diagnostic study, International Journal of
irregularities. Remedies are provided helpful for less Engineering Inventions ISSN: 2278-7461, www.ijeijournal.com,
defect casting. [8] Most work is done on irregularity Volume 1, Issue 6 (October2012) PP: 01-05
diminution in casting. Author has explained various 2. Mr. Bhushan Shankar Kamble, Analysis of Different sand
methods for defect analysis which are FEM, modulus Casting Defects in Medium Scale Foundry Industry - A Review,
International Journal of Innovative Research in Science,
method, solidification simulation using FEM and dedicated Engineering and Technology Vol. 5, Issue 2, February 2016
software for simulation such as Procast, AutoCast-X. [9] 3. Mahipalsinh G. Jadeja Manoj kumar V. Sheladiya Mayursinh
Author has provided guidelines for proficient Gohil, A Review on Casting Defect Minimization Through
implementation of simulation tool. Also paper has Simulation, International Journal for Scientific Research &
Development| Vol. 3, Issue 11, 2016 | ISSN (online): 2321-0613
explained points to be followed for making new section for 4. Avinash Juriani, Casting Defects Analysis in Foundry and Their
simulation of casting and precautions to be considered Remedial Measures with Industrial Case Studies, IOSR Journal
while casting are provided for implementation. [10] of Mechanical and Civil Engineering, Nov-Dec 2015
5. H. Kambayashi, Y. Kurokawa, Observation of Defects in Cast
Author has worked on casting of a plate for removing Iron Castings by Surface Analysis, Tsuchiyoshi Industry
shrinkage and gas porosity defects. Simulation is done in Corporation, Hiroshima, Japan, 2005.
AutoCast application. Simulation enables the visualization 6. CHIH-YUAN CHEN and KUAN-JU LIN, Forming factors of
blowhole defect in continuously-cast beam blank at Dragon steel,
of solidification. Changing feeder location, 15%
Iron and Steel Research & Development Department China Steel
improvement in yield is obtained.[11] In this review, work Corporation, 2011.
is done on a wear plate. Existing feeding system is studied 7. Praevadee Kaewkongkha, Somkiat Tangjitsitcharoen,
and imitation of new feeding system is done by using Investigation of factors affecting the blowhole in Die casting,
IOSR Journal of Engineering (IOSRJEN), 2015.
AutoCast software. During casting gates and riser were
8. A. Rai, S. K. Ganguly, WEB-BASED EXPERT SYSTEM FOR
placed symmetrically and flow was uniform, gases were SOME DEFECT IN SAND CASTINGS, International Journal of
easily escaped to the atmosphere. By using this method Advanced Engineering Research and Studies, 2015
superiority of casting has been improved. [12] 9. Prachi K. Tawele, Laukik Raut, Warpage in Casting: A Review
International Journal of Advance Research in Engineering,
Science & Technology (IJAREST), ISSN(O):2393-9877, ISSN(P):
CO N C LU S IO N 2394-2444,Volume 2, Issue 4, April- 2015
10. Dr. B. Ravi, Casting Simulation Best Practices, Transaction
Defects like shrinkage, blowhole, pinhole, sand inclusion of 58th IFC Ahmedabad 2010.
11. C. M. Chaudhari, B. E. Narkhede, S. K. Mahajan, Casting design
and sand burning can be identified and simulated. Separate
and simulation of cover plate using AutoCAST-X software for
design software is needed to design the product which defect minimization with experimental validation, 3rd
needs to be simulated. Simulation helps to manufacture International Conference on Materials Processing and
defect free casting without consuming too much time. In Characterizations (ICMPC 2014)
12. Sachin L. Nimbulkar Rajendra, Dr. S. Dalu, Design and
India, casting simulation technology is increasing rapidly.
optimization of gating and feeding system through simulation
Besides improving the existing casting, this technology technique for sand casting of wear plate, Perspectives in Science
can also be used for rapid development of new products. (2016).

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