Numerical Modelling of Sand Casting: A Predictive Framework for Process Optimization

Sand casting is a widely used, cost-effective, and versatile manufacturing process to produce a variety of metal components, however it is prone to defects like shrinkage cavity, porosity, hot spots due to improper heat transfer. In spite of its simplicity, the process is associated with extremely complex process of fluid flow and heat transfer. Mathematical modelling is an essential for sand casting. A mathematical model is developed by finite difference method with one dimensional heat transfer. In this study, a combined mathematical and numerical modelling approach is employed to analyze transient heat transfer in sand casting with the objective to monitor temperature variation and cooling rate to avoid cause of defects. The governing heat conduction equation is first formulated through mathematical modelling incorporating relevant initial and boundary conditions representative of casting- mold system. The model is then discretized using finite difference method to enable numerical simulation of temperature distribution and cooling behavior during solidification. The predicted temperature profiles showed good agreement with the analytical solution and published experimental results, demonstrating the accuracy of the proposed numerical model. The developed predictive framework provides a practical tool for analyzing cooling behavior and supports process optimization to improve casting quality and minimize casting defects. The proposed mathematical model enhances predictive capability, reducing costly trial-anderror practices on the shop floor while supporting improvements in manufacturing efficiency, time, and production cost.