Materials Today: Proceedings 22 (2020) 799–805

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Materials Today: Proceedings

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Casting design and simulation of gating system in rotary adaptor using

procast software for defect minimization
R. Kumar a, S. Madhu b,⇑, K. Aravindh c, V. Jayakumar d, G. Bharathiraja e, A. Muniappan e
a
Department of Mechanical Engineering, A V C College of Engg, Mayiladuthurai, India
b
Department of Automobile Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai, India
c
TE Connectivity, Bengaluru, India
d
Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Chennai Campus, Chennai, India
e
Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai, India

a r t i c l e i n f o a b s t r a c t

Article history: This work gives an idea of creating gating system for investment casting with the help of fascinating
Received 1 June 2019 advancements in the casting field. In this study, advanced techniques are utilized for creating a part
Received in revised form 22 October 2019 named rotary adapter. This part has a complex shaped profile and needs a high surface finish with strin-
Accepted 28 October 2019
gent dimensional tolerance. Hence investment casting has been chosen for fabricating. Unigraphics soft-
Available online 21 November 2019
ware was used for modelling the part and the gate system as per the given dimensions. Then the part is
imported to the Pro-CAST software for simulation. In this work different real time parameters were given
Keywords:
as input and the simulation was carried out. The simulation results were analysed and the defects were
Investment Casting
Gating system
identified. Different gating system has been implemented for eliminating the defects. The process was
Computer aided design repeated in the software and the efficiency was proved with defect free casting.
Unigraphics Ó 2019 Elsevier Ltd. All rights reserved.
Pro-Cast Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Materials Engineering and Characterization 2019.

1. Introduction ware modelling techniques [4]. Optimizing gating system is

Investment casting process is one of the traditional methods
used for making precision castings. It is a metal casting process
where a disposable wax replica which is identical to the casting
desired that has been produced from an injection moulding as tool
[1]. Some rules are to be followed right from the pattern prepara-
tion to the casting of metals for defect free product [2]. The causes
for defects are identified by conducting different tests in every
stage and rectified those problems by the sequence of pattern
preparations with proper allowances, sand and mould prepara-
tions, melting and metal preparations, casting removal with proper
fettling process and finally by checking the casting surfaces and
internal defects [3]. Recent technology development helps identifi-
cation0 of the defects and their causes using 3D modelling and
simulation software. Manufacture of defect free casting of pump
casing is one type of difficult tasks in industry. Proper designing
of mould and placing of gate, runner, and risers at appropriate loca-
tion help achievement of defect free casting using WINCAST soft-
⇑ Corresponding author.
E-mail address: mathumarine@gmail.com (S. Madhu).
possible for considering the fluid mechanics law together with
empirical relations and various gating elements and system [5].
The design of gate by proper fluid metal flow rule avoids turbu-
lence and slag entry into the mould. Use of casting simulation
was found to be helpful to optimize the gating system dimensions
that lead to better yield. Further reveals the help from exothermic
covers eliminating the hot spots and hence shrinkage defect [6].
The application of casting simulation software ADSTEFAN helped
the gating and raising system was rectified by so many iteration
of shifting of sprue location. Hence the porosity was reduced to
97% which is acceptable as Industry standard [7]. The basic seven
elements associated with the rigging system are important in the
calculations of the gating. This reduces the rework of gates and ris-
ers and leads to production of defect free casting [8]. Small auto-
mobile components like butterfly valve body is designed with
proper gating, runner, riser and sprue by considering the metal
flow rate and cooling rate of molten metal [9]. Different types of
software have been reviewed for the purpose of reducing the
man power needed in the design of mould cavity. Casting simula-
tion is one of the powerful tools in the casting process without
involvement of physical work. This improves the confidence of

https://doi.org/10.1016/j.matpr.2019.10.156
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials Engineering and Characterization 2019.
800 R. Kumar et al. / Materials Today: Proceedings 22 (2020) 799–805

the engineers in the functionality of feeding system with design to form a layered, seamless mould. After the ceramic was dried, the
optimisation [10]. 3D component model was developed using cast- disposable wax was melted out leaving a hollow cavity. The molten
ing simulation software ADSTEFAN to evaluate possible casting metal was poured into this cavity and allowed to solidify.
defects for the sand casting of flywheel. Different iterations, prob-
lems in design of gating, in gates, mould cavities and fluid flow
helped identification and rectification in the modelling. Eventually 2. Materials and method
sound casting of fly wheel was achieved [11].
A trash plate casting was designed basically by numerical val- Unigraphics supports of product development at all stages, stat-
ues for solidification shrinkage and gating. The experiments ing from conceptualization and going up to design, analysis, man-
showed poor quality of casting due to improper shrinkage allowan- ufacturing. NX integrates these product lifecycle stages into an
ces, then the components were iterated in 3D modelling and the end-to-end process. Foundry and casting processes have tradition-
defects were rectified by simulation with the optimized design ally been experience based and prone to trial and error based iter-
[12]. Modelling output indicated that the optimized process ative designs on the shop floor for die and mold design.
parameter with 98% defect free components was possible through Comprehensive information about what happens in the die/mold
use of different iterations and validation in the design aspects [13]. cavity, in terms of the molten metal flow, heat transfer, generation
Solid-Cast simulation software was experimented in the guiding of the heat spots, solidification process, and thereby, an ability to
face which is a body part of pulp valve made from cast iron. Use detect different defects that happen in a casting, is very useful
of this software is of immense help in designing an optimum gating for a casting designer. These advances made in the science of solid-
and feeding system that can improve the yield and the quality of ification have enabled the understanding of the mathematics and
casting and eliminate internal defects. The yield of casting from physics of casting has been well understood now. As a result, the
this design is 70.31%. By carrying out casting simulation, substan- casting process has become amenable to rigorous scientific analy-
tial quality materials, time and cost required in shop floor trials can sis, helping the design of industrial casting operations. In the last
be saved [14]. Pro Cast software which is familiar in the current decade, computer simulation based design has been adopted as a
industry was experimented in the sand casting of crusher plate. standard practice in foundry and casting industries.
Intelligent usage of this simulation software helps reduction in This simulation can be done by solving which called governing
scrap rates with optimum design factors. By many trails helped equations for physical processes and parameters for are given geo-
identification of the errors with high level of confidence and good metric considerations for a particular component and gating/mold/
quality components [15]. The components were redesigned with riser design. The equation is solved with the help of the computer
the help of theoretical knowledge, feeding rule, past experience
and gating rules and then were simulated using the simulation
program Auto CAST-X flow plus. The procedure was repeated to
get the required casting. Finally the best design was selected and
validated using actual casting process [16]. A413 light metal cast-
ing in a sand mould with proper gating design including the gate
geometry and size on the flow pattern was investigated by pouring
molten metal with different gating system.
In this study, direct observation was employed for experimental
observation the flow pattern for the mould filling. The results
showed an increase in the width of the gate with a constant thick-
ness resulting in variations in mould filling. Three different pat-
terns were observed. A considerable effect of the gate geometry
with a constant cross section area on flow pattern was observed.
A deviation of melt flow from the centre line of the mould or
incomplete gate filling tends to appear in non pressurized gating
systems [17,18]. An optimal design of two feeder system was
implemented and the casting results were analysed for its yield.
The results were optimised using Ansys 12 software and the pre-
cise feeder system was found, and then modelled by the software
[19]. Investment casting is known for its capability to produce
components of excellent surface finish, dimensional accuracy and
complex shapes. Properties of wax pattern like surface finish, per-
centage shrinkage and hardness were determined for each experi-
ment. An attempt was made to find out the set of input parameters,
which could offer a set of ideal properties of the wax blend, using
Taguchi method [20]. Key inputs, steps and results are discussed
here. However, casting simulation poses several challenges for
industrial users. Highlighting the best practices based on the expe-
rience with several casting simulation projects, and directions for
further research in this area for making casting simulation easier,
accessible and economical for industrial users [21].
Based on the above literatures, the investment casting was
experimented by modelling and by virtual trails. The wax models
were engineered to be slightly larger than the casting with proper
allowances, taking note of volumetric shrinkage of metal when it
cools from liquid to solid state. The wax patterns were gated onto
a sprue, and then repeatedly dipped into the liquid ceramic slurry Fig. 1. Process sequence of investment casting.
 R. Kumar et al. / Materials Today: Proceedings 22 (2020) 799–805 801

for the specific conditions of the particular casting process. Pro
CAST is software using the Finite Elements Method (FEM).
In this work CATIA V5 R17 Software is used to model the sub-
strate and mechtrode and the whole process is developed in non
linear finite element model. A combination of Tetrahedron ele-
ments is used for analysing the simulation model [22]. It allows
the modelling of thermal heat transfer, including Radiation with
view factors, Fluid flow, including mold filling, stresses fully cou-
pled with the thermal solution. It also includes also microstructure
modelling. Fig. 1 show the steps involved in designing the
components to shop floor for casting.
3. Part modelling
The part was created in modelling software from 2D diagram.
Fig. 2 indicated the Flow diagram of design and analysis of
components.
The minimum tolerance was ±0.3 mm. The material is a steel
alloy. The required quality is checked as per standard inspection
technique. The orientation of the model was chosen for the design-
ing of the gating system. Orientation of the part plays a major role
in designing the gating system. While designing the gating, various
parameters like shrinkage porosity, gas holes, cracks, sand trap are
to be considered. Another major factor is that turbulence is to be
reduced by maintaining the flow velocity at 0.5 m/s in the gates.
The following information was inferred from the 2D engineering
drawing, which is used in the creation of the model (Fig. 3). The
surface finish should be two triangle finishes.
After deciding the gating pathways, the gating dimensions are
to be decided as per standard calculations. From the calculations
the Gating ratio value was found to be above 1.2 (i.e. G > 1.2),
which was the essential standard to be confirmed for gating -sys-

Table 1
Specification.

Injection machine: MPI

Pattern rinsing material: Isopropyl Alcohol/Denatured spirit
No. of patterns per tree: 1 max
Description Specification
Primary liquid coating ethyl colloidal silicate
Primary Coating Zircon sand
Drying time 4h
Secondary coating Fused Silica
No. of successive coats 8
Drying time between each coat 4h
Types of dewax Autoclave Machine
Shell firing temp 1000 ± 25 °C
Shell firing time 3h

Table 2
Melting furnace input data.

Description Specification
Fig. 2. Flow diagram of design and analysis of components.
Shell preheating temperature 1000 ± 25 °C
Shell preheating time 4h
Crucible type Alumina
Crucible capacity 15 kg
Pouring Temp 1620 ± 10 °C
Pouring time 4 s (max)

Table 3
Pro CAST input values.

Description Specification
Shell thickness 8 mm
Metal Fill time 4s
Mesh element unit Millimetre
Enclosure mesh element edge length 50 mm
Mesh element edge length 2 mm
No shell face depth 20 mm
Part material Steel alloy
Shell material Fused Silica
Metal Liquidus temperature 1514 °C
Metal Solidus temperature 1462 °C
Ideal time before pouring 25 s
Fig. 3. Three dimensional model of the component.
802 R. Kumar et al. / Materials Today: Proceedings 22 (2020) 799–805

Fig. 4. (a) Flow time values. (b) Flow values.

Fig. 5. 3D model with gating system.

tem designing. Only with this value an efficient gating system to
produce defect free casting could be assured. So while designing
the gating cross sections, the gating ratio value was maintained
over entire calculation. A series of trials were done to reach an
optimized gating dimension for the foresaid part.
3.1. Technical specifications
The following input values were fed into the simulation soft-
ware for making the simulation into a real time one rather than
an ideal situation.
Fig. 6. Importing model in to Pro-CAE.
The following coating materials were selected: 1st coat = zir-
con sand, 2nd to 3rd coat = Fused silica (fine), 4th to 8th coat = -
Fused silica (coarse). Table 1 shows the specification of the
component. Table 2 shows the melting furnace input data.
Table 3 shows the Pro Cast input data. The graphs shown as
Fig. 4(a and b) depict the values given for flow time input. Ini-
tially the mould is kept idle in 25 s before pouring the casting.
This is the time required for bringing the mould from preheated
to furnace area.
 R. Kumar et al. / Materials Today: Proceedings 22 (2020) 799–805
Fig. 7. Fluid flow analyses.
Fig. 8. Temperature Contour.
4. Result and discussion
Investment casting process offers many unique benefits over
other casting processes including design freedom, tolerance,
reduced machining, superior aesthetics and reproducibility. It also
overcomes the drawbacks of many other common manufacturing
processes. A major part of investment casting process in the
designing of the sprue and gating system varies with each product.
The gating system serves as the path by which molten metal flows
into the pattern cavity and feeds during shrinkage that develops
during casting solidification. Proper design of the gating system
is critical in meeting two important requirements. Short flow paths
and fast metal flow prevent casting mis runs by avoiding prema-
ture solidification. Relatively heavy sections which solidify more
slowly require direct gating contact to provide molten metal for
feeding shrinkage that arises during solidification. Pressurized
803
Fig. 9. Fraction of solid.
Fig. 10. Gating model for Trial 2.
gating system was used in these experiments. Different combina-
tions of gating system designs and mold filling were carried out
for complete elimination overfilling defects. A gating system can
be assessed using mold filling time, in-gate velocity, impingement,
gating yield and fettling.
4.1. TRIAL 1 Gating
A gating system was designed for the first trial. The gating sys-
tem is a top pouring one. While pouring the metal, the velocity of
metal first struck in the sprue. The metal flowed through the down
804 R. Kumar et al. / Materials Today: Proceedings 22 (2020) 799–805

part. This was because the defect free part could be taken by fet-
tling away the gating system.
Solidification defect was found after interpretation of these
results. The shrinkage found at five major areas (marked in red)
is shown in the Fig. 9. The Fig. 9 shows solidification porosity at
a cut off ratio of 0.125. This value was experimentally verified by
the ESI group. Cut Off value = fraction of metal in solid/ fraction
of metal in liquid state. The porosity measured here is Macro
porosity. This inference from the above analysis is that shrinkage
occurs inside the part. Also in this model shrinkage is found to
be more (Fig. 9), which result that showed gating system is not
effective. Therefore modification had been made in the gating sys-
tem. Else a new gating system had to be developed for next trials.

4.2. TRIAL 2 Modelling

This is the second gating model shown in Fig. 10 for next simu-
lation trials. Initial feasibility of this model was under question.
But, analysing the overall dimension of the part showed its feasibil-
ity with the facilities available. In this gating system the In-gate
shape for the right side disc was changed as shown in Fig. 10. This
was done in order to move the porosity outside the part shown in
Fig. 11.The above gating system was converted to paranoid file. It
was further imported into the Pro-CAST Software for simulation.
Fig. 11. Analysis of Trial 2.
Simulation was again executed after providing all input values.
The metal filled part looked as shown in Fig. 11.
Table 4
Gating calculation. 4.3. Trail 2 analysing
S. Parameter Left disc Right disc(including
No fins) Analysis of the same kind as in the previous was carried out for
1 Gating cross section Ø25 and Ø40 for Ø32 and Ø50 for 80° trail II and the defects fou0nd are shown Fig. 4. Temperature con-
28° tour and fluid flow analysis were done. Fraction solid analysis was
2 Gating length 30 mm 40 mm also done at a cut off value of 0.125. Interpretation of the result in
3 Gating area 11900.078 mm2 7192.4 mm2 various methods of analysis provided following inference. After
4 Gating volume 48324.9317 mm3 22340.2144 mm3
solidification, Trial 2 was compared with Trial 1. The gating system
5 Gating modulus 1.7423 mm 3.106 mm
(Mg) in Trail 1, showed occurrence of five numbers of defects in which 2
6 Casting area 11900.078 mm2 51733.4562 mm2 inside the casting and 3 away from the casting (Fig. 11). In the sec-
7 Casting volume 48324.9317 mm3 113123.2057 mm3 ond gating system only 2 defects occurred. These defects occurred
8 Casting modulus 1.7423 mm 2.18665 mm
away from the casting in the area of runner and gating. So these
(Mc)
9 Gating ratio (Mg/ 2.33 1.4204 defects had no effect on casting. Hence the second gating system
Mc) was finalized for production in the shop floor. Table 4 depicts the
gating calculation steps for calculating gating ratios. Values of gat-
ing ratio can be seen above 1.2. So defect free casting could be
assured.
runner and the metal filled at the bottom of the runner there by The component rotary adopter was drafted and designed as per
elimination of the turbulence. the dimensions by the sequences of work as mentioned in the flow
The sediments or solid inclusions from the fluid were at the bot- diagram. The 2D drawing for the component was developed con-
tom of the gate. Hence clean metal flowed into the in-gate. Here sidering good surface finish with tolerances. The gating system
various shapes of the in-gate were specified for providing smooth was designed considering various factors like flow velocity, heat
metal flow. This gating model was imported into Pro Cast software transfer, coating materials on the surface of the cavity and further
and the simulation was run. The model with gating system is it was designed with a gating ratio of above 1:2 with 1.5 m/s of
shown in the Fig. 5. After the import of the model in to Pro Cast, fluid velocity as per the specification in Tables 1 and 2. The trail
the required input parameters were given and simulation was was conducted by giving proper input values in Pro Cast software
started. Fig. 6 shows the imported model of component in Pro-E and run the modelling simulation. Fluid flow analysis, tempera-
software. ture, contour and hot spot were observed during the modelling
When the simulation was running the model observed as and analysed for ensuring the gating system for defects free cast-
below, while the metal is being filled. The above gating system ing. In Trial 1 showed the gating cut off ratio of 0.125, and devel-
was converted to parasolid file with an enclosure. This enclosure oped five shrinkage defects as marked in red colour. The places
was included to give the radiation heat transfer value. The simula- of hot spot/shrinkage defects were identified, two in the casting
tion was run in 8 processor computer for 6 h. Various result inter- surface and three away from the casting which was nearer to the
pretation methods were applied when the simulation was gate and runner hole. This type of gating system was modified by
completed. After metal filling, the part was allowed to cool. The another design to eliminate defects in casting. In Trial 2 the new
rate and position of the cooling of the part are shown in Figs. 7 gating was developed for defect free casting. The gating was mod-
and 8.The results show various islands of hot spots. The hot spots ified with multiple in-gates instead of the single solid gate. The
developed into solidification defects or shrinkage porosity, new model in Trial 2 was simulated and analysed. The analysis
requiring moving to the gating system i.e. moving away from the showed the gating cut-off ratio lying between 1.4204 and 2.33
 R. Kumar et al. / Materials Today: Proceedings 22 (2020) 799–805
caused defects free casting could be assured. After solidification the
casting had two defects and identified as a red mark in the gate
area. This was done in order to move the porosity outside the cast-
ing. These types of gating design assured defect free casting. The
following conclusion may draw in the design of gating by using
simulation software. From this work it was noticed that the design-
ing time was very much less compare to conventional method. The
number of options available for design suitability is high. The
design and manufacturing cost are low. Visualisation of mould fill-
ing phenomenon makes the process easy. Defects and hot spot
locations are easily identified. Finally, the product quality is
improved with increase in yield and less rejection.
5. Conclusions
The casting process was simulated using Pro-CAST and by
assigning pouring temperature, flow rate, shell transfer time, heat
transfer coefficient, proper materials (shell and metal), radiation,
gas entrapment. Based on the simulation it was seen that the gat-
ing system was modelled by considering various parameters such
as flow length, air, foreign material entrapment, in gate velocity
and gating ratio. The result in each stage was interpreted through
different methods like in gate entry velocity method, Fraction Solid
method, Shrinkage porosity method and all the necessary modifi-
cations are made accordingly. The modified gating system was
simulated; analysed for defects and found defect free in simula-
tion. From this experimental investigation, it was observed that
the new gating system would help consistent production of sound
castings with the aid of NX and Pro-cast software.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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