Analysis of Casting System Design of Using a Computer-Aided Simulation

Due to casting defects, the Akaki Basic Metals Industry (ABMI) encounters a significant rate of rejection and rework concerning flange roller products, exacerbating manufacturing lead times, increasing production costs, and diminishing customer satisfaction. According to the factory production reports, 89 flange roller cast parts were rejected due to casting defects, resulting in a financial loss. The primary factor contributing to the casting defects that lead to product rejection is the inadequacy of the gating and feeding system design, coupled with ineffective process control. Consequently, the primary objective of this paper is to analyze the casting system design for the flanged roller utilizing a computer-aided simulation methodology. To achieve this goal, the existing gating and feeding system of the flanged roller is modelled using CATIA V5, and simulation analyses are performed employing ProCAST 2019 casting simulation software. From the simulations, shrinkage porosity and hot spot defects have been identified as the principal defects present in the product. In summary, it is concluded that computer-aided casting simulation facilitates the company's ability to preemptively manage defects prior to their occurrence in the physical production environment.