International Journal of Recent Technology and Engineering (IJRTE)

ISSN: 2277-3878, Volume-8 Issue-4S2, December 2019

Effectiveness of Feeding System for Enhanced

Product Quality in Sand Casting Industries
I.Rajkumar, N.Rajini

 this context [6]. This was possible due to the existence of

Abstract: This review article deals with the importance of atmospheric temperature suitable for the casting process.
process parameters and the recent developments in modern tool Indian casting industries are actively involved in the
technology in the success of smart productivity for casting process development of casting products in various applications. A
of all types. Various influencing factors such as design, location suitable process has to be selected from among several
and the number of gating on feeding mechanism were discussed
processes based on the requirements of the product and the
vis-a-vis casting defects. The review revealed reduction in the
defects such as air bubbles, blow holes, shrinkage defects and area of its use. Hence, every industry is keen on selecting the
mechanical properties of the casting parts through selection of an casting processes that would answer the mandatory
optimum feeding design. Variations in fillet radius and thickness requirements with minimal production cost [7]. There are
on the feeding system were found to be the factors affecting the various factors that need consideration before the selection of
location of the hot spot. Accordingly, the mobility of the hot spot the casting process. Mechanical properties like hardness and
was controlled by geometrical modifications in the feeding system. tensile strength have been identified as important criteria for
In addition, the formation of pinholes and solidification defects any casting part before having put into use [8]. It has been
could be reduced through a proper arrangement of the feeding
proved that sand casting and pressure die casting parts can
system. The rapid growth in implementing simulation techniques
in the casting process can assist the enhancement of yield with offer enhanced mechanical properties as confirmed from the
minimum production cost. This article provides a data base earlier published work [9-10].
relating to the merits and demerits of various factors and material
Currently, there are many new technologies under
systems with their industrial applications for enabling further
research in the casting process. implementation in casting industries. However, most of the
Keywords : Casting, , hot spot, shrinkage, simulation, yield small scale casting industries are struggling to produce quality
products is an economical way for different materials. Some
I. INTRODUCTION review articles have been published relating the casting
process in the aspect of the role of simulation software by
Despite the metal casting process being one of the oldest considering the various influencing factors for different
applications [11-12]. The various types of casting defects are
processes in the fabrication of metal components, shown in Fig.1 At the same time, there has been no
advancements in research are still required for obtaining considerable exploration of the design of the feeding system
quality products through cost effective ideas [1]. In particular, on the performance of casting products seen in the research
problems like quality control, low production, energy articles published so for. Hence, this review article addresses
efficiency, reduction in material consumption and the impact the significance and applicability of a feeding system in the
of environmental production are frequently seen in modern casting process for providing the significant information that
casting industries. In recent days, extensive research has been can help achievement of mass production with minimum time
done in the aspect of optimization on the casting process to consumption.
identify the parameters affecting quality measures [2-3].
Accordingly, factors such as mould material, poring basin,
runner and gating system have been found to have a
significant effect on product quality in the casting process
[4-5]. Hence, it is mandatory to create a database with key
findings seen in published articles with respect to casting
parameters on quality measures that would be useful for small
scale casting industries.
A recent survey on casting market reports that the countries
like China, US and India have made substantial improvements Fig. 1. (a) shrinkage cavity, (b) shrinkage porosity, (c) canter line shrinkage,
in the production of the casting components. In particular, (d) corner shrinkage and (e) surface sink. [44].
Asian counties such as China and India are in the forefront in
II. SAND CASTING PROCESS
Revised Manuscript Received on December 05, 2019.
* Correspondence Author Sand casting is one of the most widely used casting
I.Rakumar*, Department of Mechanical Engineering Kalasalinagm methods followed by small scale casting manufacturers due to
Academy of Research and Education, Krishnankoil, Virudhunagar, Tamil its advantages like low initial investment cost, versatility in
Nadu, India. Email: irajkumarilango@gmail.com
casting design and recyclable
N.Rajini, Department of Mechanical Engineering, Kalasalinagm
Academy of Research and Education, Krishnankoil, Virudhunagar, Tamil mould sand. It is also
Nadu, India. Email: rajiniklu@gmail.com eminently suitable for various

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 Effectiveness of feeding system for enhanced product quality in sand casting industries: A review

metals and alloys like nickel, copper and iron that are known traps. Factors like the shape and the size of the feeder and
for high melting temperature. The process starts with the feeder neck, location of the feeder, insulating sleeves and
molten metal poured into a sand mould and allowing it to covers, fins and chills have been taken into account in
solidify at room temperature. The sand mould is then broken designing the feeder system to avoid shrinkage defects at
and the final finished casting product is removed. Fig.2 shows different regions [20]. At the same time, a perfect gating
the various steps and components involved in the sand casting system can ensure smooth, complete and uniform filling with
process. Previous research work shows defects such as less time enabling detection and elimination of many defects
improper pattern, wrong gating system, poor of sand quality,
molten metal composition affecting the performance of the B. Based on component orientation of gating system
sand cast products [13-14]. The main purpose of introducing the gating system is to
connect a number of casting cavities for achieving higher
productivity [20]. On the other hand, in the horizontal feeding
system, the symmetrical arrangement of gating was found
more suitable for a thick wall casting, exhibiting uniform
temperature distribution, flow and air entrainment. In
addition, the simulation results show the possibility of a 30%
reduction in rejection arising from feeding system related
defects. Researchers have also analyzed the defects after the
machining on plate at various thicknesses 5 and 10 mm
components using ultrasonic test results [21] and found no pin
holes or gas porosity. The results have exhibited
achievements of a good surface finish of the product using a
Fig. 2 Steps and components of sand casting process. dry sand mould. On the other hand, the percentage of porosity
Further, parameters like the grain size and bonding material was found to be low in the case of air-set sand mould
are also found to play a significant role in achieving a quality compared to other types of sand mould. Further, air-set sand
casting product [15-16]. However, the design of the feeding moulds produced class thin-walled sand cast components of
system is identified as the key factor for producing good below 1.5 mm thickness with the use of the combined effect of
quality parts with the least cost. However, the selection of an additive layer manufacturing and casting simulation
effective feeding option is no easy job due to variations from techniques [22].
component to component, requiring an extensive trial and
error process [17]. C. Based on Gating and Riser Location
A research work was carried out on the runner design (main
A. Significance of feeding system in casting process and side runner) in obtaining defect free quality product.
It is well a known fact that the efforts of all the small scale Modification in the straight runner as a tapered runner and a
sand casting industries are towards achieving quality products reduction in oxide layers were found. The straight runner flow
at a low cost. Consideration of the design of the gating system allows air entrainment and produces uneven filling shown in
is inevitable for achieving success in this task [18]. Fig.4 Increased filling ratio and uniform metal entry were
Accordingly, industries are trying with 'Right the First Time' observed in the tapered runner flow. A change in the fillet
approach to minimize time consumption. However, radius of tapered runner was done automatically using design
attainment of this in the real time sand casting process is no optimization with MAGMASOFT. Further, different
easy task. Hence, lots of trial and error methods are still being optimization goals were used for achieving a quality product
undertaken by small scale industries. with minimum production time through control over the
various manufacturing parameters like geometric feeder
system (location and shape and size of runner, gate, riser) and
chills [18]. In one of the works, the gating system design was
done for eliminating the oxide layer and sand inclusion that
occurred due to the existence of the turbulence flow.
Experiments were carried out using two different gating
designs, namely, the pressurized gating system (PGS) and the
new version gating system (NVGS) for achieving this. Fig.5
shows the defects in the casting were analysed with the
support of a simulator software. Results indicate melt velocity
Fig.3. Elements of a typical gating system [20]. as one of the critical factors leading to the formation of oxide
layer based on the type of flow. Accordingly, casting products
On the other hand, large scale industries have started formed by NVGS design do not exhibit any oxide layers and
implementing the simulation techniques which are found to be sand inclusion defects. This was eventually confirmed from
less time consuming in the selection of the optimum the final inspection using a scanning electron microscope and
parameters for appropriate condition. In the forthcoming Energy Dispersive Spectroscopy analysis [23].
section, various designs of gating systems are discussed with
the support of experimental and simulation results [19]. Fig.3
shows the casting components with the experimental set up of
a runner, liquid basin, sprue, well runners, gates and slag

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DOI:10.35940/ijrte.D1048.1284S219 Blue Eyes Intelligence Engineering
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 International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8 Issue-4S2, December 2019

In another study, a casting valve-type product was analysed

using the numerical simulation technique [26]. Based on the
results, the performance of the casting part in the aspect of
solidification sequence, filling behaviour and thermal stress
distribution were discussed and the reasons for the formation
of defects such as cold shut and shrinkage were also
predicted. The results suggested a single-gating system as an
alternative to the double gating system for the valve -type
product. The need for chills for the same product was also
Fig. 4. Different runner design and its defects (a) straight discussed through reduction in defects with enhanced quality
runner, (b) Oxide defects, and (c) optimized taped runner [19] product, the usage of multi cavity with different feeding
. systems was investigated for the brake disk in automobile
applications by researchers [27]. Three different layouts were
proposed using a modified design with respect to geometric
parameters shown in Fig.7. Accordingly, changes like
dimensions of runner, curved of runner, down sprue point of
connection runner, cross section of down sprue dimensions
and dimensions of ingate and position have been proposed in
the new layouts for improvements in the quality cast obtained.
However, an optimized streamlined feeding system was
identified on the bases of the simulation results. Results
showed reduction in air entrainment and turbulence flow with
minimal material usage which facilitated the enhancement of
Fig. 5. Layout of (a) PGS design with lap gate and (b) NVGS
casting yield from 73% to 77% [27-28].
design with edge gate (Arrow shows magnified lap and edge
gate) [23]
Recently, the importance of reducing hot spots through an
appropriate design of feeding system with respect to
directional solidification was analyzed [24]. Literature shows
the ability of the optimized feeder placement to enhance
casting yield up to 15 % with the outcome of defect free
casting and with a minimum number of experiments. Results
of analysis obtained from the simulation of Auto Cast-X
software (Fig.6) help visualizing the progress of hot spot, and
in turn, exhibit the formation of shrinkage defects. Moreover, Fig. 7 Various gating design of brake disk filling:
a perfect design of feeding can help attainment of guiding conventional (upper) and optimized streamlined gating
solidification with a decrease in failure due to spot system (lower) [28].
solidification and incomplete filling [25]. In another research,
Different optimization techniques were used for the
Results showed the four-cavity mould as effective more than
selection of an appropriate quality system [29]. In this regard,
the three-cavity system, in achieving a quality casting product
a study explains the importance of gating location using the
in both cast parts. The risk of formation of micro-shrinkage
Genetic Algorithm (GA) optimization technique for the
could be minimum to with the case of a centre cavity rather
excavator bucket component [30]. Based on the results, the
than going in for a side cavity. The developed model
optimum feeding system was seen providing good results with
suggested reduction in cross-sectional area for the first gate to
reduced consumption of molten metal with the added benefit
diminish the possibility of air entrapment. The effects of
of achieving quality casting parts. Parameters like ingate cross
various parameters such as melt superheat, pouring time
sectional area and ingate height were identified as the
(velocity), mould surface roughness, gating design, and the
supporting elements of optimized geometry feeding system
mould configuration on the quality casting product could be
for the getting better results compared to the previous
studied, using this model [26].
processes.

D. Based on type of Gating System

In this section, single and multi-gating systems for different
applications with the support of some of the reported works
are discussed. The metal flow sequence through the multi
gating system for different materials was analyzed by Ravi
and his associates using a simple experimental setup shown in
Fig.8 The result showed variations in output parameters such
Fig. 6 Cover plate simulation with use of AutoCAST-X, (a) as entry of metal flow in gating and sequence of flow and flow
Identifying the shape complexity of the part (b) Feeder rate based on the materials. They have also developed an
location at hot spot [25]. empirical relation based on
the experimental data
obtained for the percentage of

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 Effectiveness of feeding system for enhanced product quality in sand casting industries: A review

flow rate through the four gates. The results have led the in molten metal took place due to the back follow dynamics
selection of appropriate material for correct gating system which trigged the refilling of the unfilled volume and thus
from the simulation model various condition as reported by wastages of material can be minimized by 11% [35].
researchers [20]. The same research group have referred to an
earlier case of the study of numerical simulation of flow of III. KEY FINDINGS FROM SAND CASTING PROCESS IN
water and aluminum alloy LM6 through a multi-gate gating VARIOUS ASPECTS
system which has been pictorially represented [31]. Results
showed increase in the discharge of molten metal 1.7 times A. Surface roughness
that of water. They have analyzed eleven sets of iteration with  Sand grain fineness and poring temperatures are also
different gating systems using the end sprue arrangement. being identified as the factors affecting the surface
Researchers have designed a novel multigate by connecting roughness in the sand casting process [16].
three gates in various 3D-L junctions with the runner. This  The surface quality was seen as depending mainly on the
design shows the velocity of the stream as equal even with the type of the sand used in the casting process.
occurrence of pressure drops. The coefficient of discharge Accordingly, air-set sand have been found exhibiting
(Cd) for the single (L1 - junction) and multi - gate runner better surface finish compared to other sands namely,
system was also measured. In both cases, the Cd values were dry sand and sodium silicate sand [22].
almost the same and followed the fiction loss of 30%  The type of molten metal flow during mould filling has a
applicable for all the filling system. The filling time for this major influence on surface quality. Accordingly, the
conduction was 1.43 time longer than friction free condition formation of vortex flow leads to the increasing surface
[32]. roughness which is seen occurring due to the mould
erosion. Hence it is important to avoid vortex flow type
to obtain the smooth surface finish [36]
B. Geometric modifications
 The design of a tapered runner and an increasing runner
radius can avoid uneven metal entry into the component
and eliminate the formation of oxide layers [19].
 Horizontal feeder: It enables getting minimum
solidification and air entrainment defects, which are
observed via ultrasonic testing of rectangular shaped X
metal casting component [21].
Fig. 8 (a) Water flow experimental setup and Mould assembly  In four cavity pressure plate application, the major
for metal pouring [20]. design changes like increasing the poring cup area are
known for automatic decreases in metal pressure,
In one of the studies, the filling process on sand casting
reduction in the runner thickness caused change in the
product of AC4C material was monitored through in-situ
flow in turbulence to laminar flow [23].
process using X-Ray apparatus. Results indicated minor
 Single down spure feeder design can lead to a reduction
effects from change made in the liquid melt flow based on
in cold shut shrinkage and crack formation defects
back pressure of gas in the mould cavity for the pressurized
compared to the two down sprue system in the case of
feeding system and sand mould with perfect air permeability
steel part valve body [27]
[33].
 Proper positioning of chills and risers facilitates uniform
The importance of feed path with respect to the distribution of temperature during the solidification
solidification process and generation of hotspot was discussed process. This can minimize shrinkage defects [37].
through the use of a new model called gradient vector method  Shrinkage porosity is reduced due to minor changes at
[34]. The results of analysis of this method were compared outer radius, inner radius, thickness, length, angle and
with those of the other two methods, namely, Modules chamber for the L, V and Box shape LM25 component
Vectors Method (MVM) and Level Set Method (LSM). [38].
Though, MVM and LVM models exhibited good agreement
C. Numerical Simulation
with the experimental results revealing the hot spot mobility,
Gradient Vector Method (GVM) was found to be superior due  In the case of mass production, uneven metal entry can
to the benefits of time saving, yield optimization and be minimized through proper selection of the optimum
suitability for multi junction casting with respect to various runner design using MAGMASOFT simulation software
boundary conditions [34]. The faster rate of filling system for which is also used for analysis of the filling time and air
entrainment [19] in the cast product. The simulation
GVM and other simulation results obtained through LSM.
results for different metal castings using the gating
The reduction in wastage of Co- Cr-W alloy for a selected
system.
mould design was discussed using ANSYS®FLUENT flow
simulation. Results indicated the role played by the variation  The mobility of hot spot and temperature distribution
in the design of gating system and gate location in the casting can be analyzed with the use of Auto-Cast X1 software,
quality, minimizing the metal wastage, increasing the refilling which was demonstrated in rectangular wear plate with
character and avoid the unfilled errors. The changes in the the effect of varying location of feeder design [21].
extension of riser gate fillet radius can facilitate back pressure  Similarly, FLOW Cast
and, in turn, eliminate unfilling errors also. As a result, a rise software can also be used

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 International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8 Issue-4S2, December 2019

for identifying the hot spot and the solidification process A. Angle gate
[22]. This simulation results showed good agreement This can be used for specific applications. Regarding the
with the experimental results for the application of the design, the structure of the angle gate (Refer Fig.9 a) is almost
engine block. equal to that of the edge gate but this provides a small angle of
 MAGMA software was found to be an efficient tool for inclination with respect to horizontal. Normally, this gate is
identifying a suitable gating type which can help attached to the component at the machined edge to enable
reduction in the formation of turbulence flow [23]. filling the hot spot first.
Further, factors like mould filling time, velocity of
casting, porosity and identification of hot spot can also B. Center gate
be simulated using this software [30]. The center gating system is appropriate only for the
 Solidification sequence, solid fraction time and components with a thicker cross section at the center and the
temperature distribution were analyzed using Flow 3D extension of center lever. The center gating is simple in
software for break disc and flywheel application. construction and can produce a higher yield compared to the
previous two gating systems (Fig.9 c). However, the quality of
 NOVACAST software was used for identifying the the product is found to be not up-to the expected level of
volume flow rate and filling time [31] in LM6 cast
accuracy due to the existence of turbulence and uneven
component.
filling. Further, it can be used only in some special cases
 The optimum gating design and gating location can be where the component has the machining surface only at the
identified using ANSYS FLUENT simulation software top face.
which would help to enhance the yield [35].
 ProCast software was used for simulating the heat flux C. Edge gate
and heat transfer coefficient of the cast component. Use Gating system of this type has a simple structure connected to
of this software, helps finding good accuracy in the component through the front face of the edge gate (Refer
simulation result for the heat conduction study in Fig.9 e). Edge gate design can facilitate smooth flow of metal
cylindrical casting model [39]. and can therefore, minimize the formation of hot spots and
 The dynamic poring method was seen as better than the eliminate porosity and holes defects. This design is well
ProCast simulation results obtained from the top and suited specifically for plate shape components having smaller
bottom poring methods. This is a movable gating system thickness (approx. < 25 mm thick).
which can be positioned at the top of liquid metal
surface [40].
 ProCast simulation was carried out on WE54
magnesium alloy with the effect of different riser
diameter. Results showed 60 mm riser diameter with the
riser length of 80 mm length riser as the most suitable
[41].
 ProCast software with the simulation of sand casting
process. The simulation results, showed the slot gate
system exhibiting a better performance than the bottom
gating system with respect to solidification and
shrinkage porosity [42].
 The simulation result was one of the important aspect of
the cast research. Reduction in casting defects like
shrinkage porosity, blowhole and pinholes present in the
case of contact wheel were found through the selection
of a proper optimum feeder design with the help of
AutoCast simulation software which leads to the
Fig. 9 Geometric structure of (a) Angle gate, (b) Cut section
optimum yield of the casting [43].
of Angle gate, (c) Centre gate, (d) Cut section of centre gate,
(e) Edge gate, (f) Ring gate and (g) Cut section of ring gate.
IV. RESEARCH GAPS AND FUTURE PERSPECTIVE OF
METAL CASTING PROCESSES
D. Ring gate
A detailed review process, led to the observation of only few It is suitable only for cylindrical components like pinion
research focus on the study of molten metal velocity can leads housing (pipe shape components). It goes into the selection of
to minimum the casting defects such as oxide layers, internal other types of gating systems for the cylindrical components
cracks, flow marks and porosity. The manufacture of thin wall which create flow marks, porosity and below hollows defects.
sand casting product has been found to be limited, requiring Generally, the design and structure of the gating for
further attention towards achieving optimum pouring manufacture are complicated. Fig.9 f, demonstrates the usage
temperature and riser and gate location. Achievement of this of ring gate in circular components. In the case of edge gate
can help getting the common data base with the information selection, this component can
on suitable pouring temperature for the corresponding wall direct the molten metal to hit
thickness. the cylindrical wall and to

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 Effectiveness of feeding system for enhanced product quality in sand casting industries: A review

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ACKNOWLEDGMENT
23. A. Modaresi, A. Safikhani, A. M. S. Noohi, N. Hamidnezhad, S. M.
The authors wish to thank the Department of Mechanical Maki, “Gating System Design and Simulation of Gray Iron Casting to
Engineering, Kalasalingam University for their permission to Eliminate Oxide Layers Caused by Turbulence”. Int. J. Metalcast
carry out the preparation and testing of the composites and vol. 11(2), 2017, pp. 328-339.
wish to thank the Department of Science and Technology, 24. H. Iqbal, A. K. Sheikh, A. Al-Yousef, M. Younas, “Mold design
optimization for sand casting of complex geometries using advance
India for funding through FIST Program simulation tools”. Mater. Manuf. Processes, vol. 27(7), 2012, pp.
SR/FST/ETI-275/2010. 775-785.
25. C. M. Choudhari, B. E. Narkhede, & S. K. Mahajan, “Casting design
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AUTHORS PROFILE
I.Rakumar, received the Degree in mechanical
engineering and master degee in CADCAM, He is a
Associate Professor of mechanical engineering,
Kalasalinagm Academy of Research and Education,
Krishnankoil, Virudhunagar, Tamil Nadu, India.
research areas of interest metal casting.

N.Rajini, received the Degree in mechanical

engineering and master degee in Engineering Design,
He is a Professor of mechanical engineering,
Kalasalinagm Academy of Research and Education,
Krishnankoil, Virudhunagar, Tamil Nadu, India.
research areas of interest are polymer Nano
composites, He has published 87 papers in various
international journals.

Retrieval Number: D10481292S219/2019©BEIESP Published By:

DOI:10.35940/ijrte.D1048.1284S219 Blue Eyes Intelligence Engineering
237 & Sciences Publication