Sand Casting Defects Analysis from Heat Transfer Simulation by Using Cast Designer
Keywords:
sand casting, heat transfer, shrinkage porosity, pouringAbstract
In sand casting processes, one of the most common defects is shrinkage porosity, which is caused by uneven heat distribution during solidification. Areas with higher heat accumulation cool more slowly, leading to rapid contraction and void formation in the material. This study investigates a single-pattern sand casting model without a riser, analyzing the heat flow using Cast Designer software. Initial attempts to resolve shrinkage by adding cylindrical hollow vents with diameters of 8 mm and 15 mm were unsuccessful. Cast Designer was employed to simulate heat transfer in the casting to identify areas with excessive heat accumulation. The results showed that the shrinkage porosity can be reduced to only 0.16% by placing vents in the areas with the highest heat concentration. The study concludes that optimizing the venting system in these specific areas is essential for minimizing shrinkage porosity.
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