Materials Today: Proceedings 59 (2022) 598–604

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Simulation and experimental analysis of re-design the faulty position of

the riser to minimize shrinkage porosity defect in sand cast sprocket
gear
Beza Tadele Bekele a, J Bhaskaran b,⇑, Solomon Dufera Tolcha a, Mengistu Gelaw a
a
Department of Mechanical Engineering, Adama Science and Technology University, Adama, Ethiopia
b
Mechanical Engineering, Larsen & Toubro- EduTech, Chennai,Tamilnadu, India

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

Article history: Shrinkage porosity is known to occur when feeding is cut off due to several reasons that can cause an
Available online 29 December 2021 early solidification of the molten metal on the riser affecting the overall feeding process. Casting simula-
tions can give a clear understanding of determining the existence of shrinkage porosity by considering
Keywords: variable process parameters like the improper design of a riser and faulty positioning of the riser. This
Shrinkage porosity research work aims to investigate and minimize the occurrence of the open shrinkage porosity resting
Re-design the riser on a sprocket gear made of Carbon steel Material. The design of the gating system was done using
Gating system
Modulus Methods, and 3D Model was prepared by using CATIA software. The optimization of the feeding
Casting simulation
PROCAST software
and gating system is conducted using PROCAST software, taking into account the actual casting data from
the foundry and the experiment was conducted to validate the simulation results. The analysis of
PROCAST predicts that the position and feed volume of riser is the key factor for sound casting by show-
ing porosity concentration is less and casting experimental result validates the increase weight final cast-
ing than earlier. An improvement in the overall quality of the product was observed when compared to
sprocket gears produced in the foundry before.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Third International Con-
ference on Recent Advances in Materials and Manufacturing 2021

1. Introduction bility for the occurrence of shrinkage porosity. Albeit the riser is of
sufficient size and placed at the proper location, sand inclusions
Casting is a process that brings the risk of failure occurrence also can stop the flow of the molten metal into the mold cavity.
during all the process of accomplishment of the finished product. Shrinkage defects can be of two different types: open shrinkage
Most casting defects are concerned with process parameters, hence defects and closed shrinkage defects. Open shrinkage defects are
casting defects may be the result of a single cause or a combination open to the atmosphere, therefore as the shrinkage cavity formed
of causes. A quality casting in a foundry is the one with a minimum by air compensates. There are two types of open-air defects: pipes
number of defects because it is challenging to produce defect-free and caved surfaces. Pipes form at the surface of the casting and
casting products [1]. burrow into the casting, while caved surfaces are shallow cavities
Shrinkage defects occur when feed metal isn’t available to catch that form across the surface of the casting closed shrinkage defects,
up on shrinkage because the metal solidifies. Shrinkage porosity is also known as shrinkage porosity, are defects that form within the
one among the casting defects which will arise when feeding is casting [2].
stop, and because the metal continues to solidify the pressure In most of the materials, the density will change on the temper-
within the remaining metal pool decreases. At an equivalent time, ature drop. It is also true that because the temperature decreases,
segregation causes gas content to extend. A molten metal reservoir molted materials will turn solid. This causes casting defects like
or riser is placed at these locations where there’ll be a high proba- shrinkage cavities that the casting solidifies from the outer surface
to the inner part while the volumetric contraction cannot be com-
pensated. Several closed molten metal areas surrounded by a metal
⇑ Corresponding author.
solidification during the method of casting solidification are called
E-mail address: bhaskaranj@[Link] (J Bhaskaran).

[Link]
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Third International Conference on Recent Advances in Materials and Manufacturing 2021
B. Tadele Bekele, J Bhaskaran, S. Dufera Tolcha et al. Materials Today: Proceedings 59 (2022) 598–604

‘‘isolated liquid areas”. It’s easy to know that isolated liquid areas gation and shrinkage micro porosity zones in a massive riser and
cannot feed each other and every shrinkage cavity generated is based on this information in the future to suggest the criteria for
the annihilation of an isolated liquid area. Shrinkage cavities prediction of chemical composition and the segregation extent in
greatly influence the mechanical properties of castings [3]. heavy castings.
The gating system was optimized [4] due to which various cast- The observed solidification simulation enables visualization of
ing defects and the manufacturing lead time were significantly the progress of freezing inside a casting and identification of the
reduced. The component was examined for defects by testing last freezing regions or hot spots [11]. This facilitated the opti-
under an optical microscope, and it had been found to contain mized placement and design of feeders with improvement in yield
hot tears, shrinkage porosities, gas porosities, and flow marks on by 15 % while ensuring casting soundness without expensive and
the surface of the component. This was improper gating system time-consuming trial runs. Simulations are often of great use in
which had to be rectified and optimized. A replacement spoon- optimizing the feeder dimensions and increasing the feeding
fed gating system was designed in order that the molten metal efficiency.
flows into the die cavity with uniform filling and lesser filling time. The mathematical modeling of solidification of 4-ton steel ingot
Improved the planning and manufactures is needed a defect- casting using ANSYS simulation software was presented [12]. The
free casting especially volumetric shrinkage defect and yield [5]. Model includes the phenomenon associated with fluid flow, tem-
The part taken for the study is Contact wheel from one of the cast- perature distribution, liquid fraction, and solidification time at var-
ing company in Aurangabad, Maharashtra. The company suffers ious instances of solidification was examined.
from casting defects like shrinkage, blowhole, and pinhole. Casting Researchers have generally studied the different techniques
solidification is quickly simulated to view the progress of cooling that can be applied to overcome casting defects, specifically shrink-
from the casting surface to the interior and predict the location age porosity. Even though, foundries are having more difficulties
of shrinkage defects such as porosity and cracks. This helps in ver- during casting giant products than small castings, due to the com-
ifying and optimizing the planning of feeders, which may be veri- plexity to identify the root cause for the defect in casting huge
fied by advanced simulation. This simulation result was compared products. But most of the experiments were performed on a small
with the experimental trial, and the comparison result was found casting, where there is a low probability for casting defect occur-
to be good. rence. As it is known, it is simpler to control casting parameters
Predictive methodology of shrinkage porosity defect within the in small-scale casting than the large-scale casting.
sand-casting process of LM25 using experimentation and ANSYS The foundry understudy suffers from poor quality and low pro-
was proposed for defect free casting [6]. Prediction of shrinkage ductivity due to the involvement of faulty process parameters. In
porosity distribution in Al-Si casting and determining the effective- many cases, the casting defects may be discovered at the machin-
ness of investigated function for predicting shrinkage porosity by ing stage, at the assembly stage, or during the use of the compo-
correlating results of simulating studies to those obtained experi- nent; which is one of the challenges that make fault detection
mentally was successful. difficult.
The study is presented to optimized framework based on CAD Here introduce the paper, and put a nomenclature if necessary,
and simulation technology [7]. CAD model had given a part design in a box with the same font size as the rest of the paper. The para-
and after converted to a casting model. After analyzing simulation graphs continue from here and are only separated by headings,
results, the gating/riser system design is optimized to enhance subheadings, images and formulae. The section headings are
casting quality. In this study, journal bearing is employed to verify arranged by numbers, bold and 10pt. Here follows further instruc-
the effectiveness of the optimization method it had been compared tions for authors.
with the initial design. The casting simulation process can ready to
solve these problems. The simulated results were also compared
with the experimental works.
2. Problem identification
The multiphase model that predicts melt pressure, feeding flow,
and porosity formation and growth in steel castings during solidi-
The main objective of this research work is to minimize the
fication [8]. By combining Darcy’s law, which governs fluid flow
rejection percentage in Sprocket gear blank obtained from casted
within the mushy zone, with the equation for Stokes’ flow, which
carbon steel material. The net weight is of 708 kg, pitch = 300 m
governs the motion of slow-flowing pure liquid, it’s possible to
m, Do = 1,150 mm and tooth thickness = 130 mm. As can be seen
derive a momentum equation that’s valid everywhere within the
in Table 1 below, the shrinkage porosities were observed with a
solution domain. The multiphase model has been successfully
necked eye, which becomes visible immediately after fettling.
implemented in a general-purpose casting simulation code, valid
for both micro porosity and macro porosity, and is capable of pre-
dicting both shrinkage cavities and riser pipes as well. Table 1
The parameters affecting the quality of the trash plate casting is Observation of Shrinkage porosity in existing sprocket gears.
to establish a standard that provides for sound casting was pre- Sprocket gear (Product)
sented [9]. To carry out the research mixed (experimental and the-
oretical) methods that include physical observation, photographic
analysis, interview, testing, and simulation methods were used.
Purposive and convenience sampling technique was used for sam-
ple selection and sampling. Modeling of trash plate and gating sys-
tem elements was first developed using CATIA software and
simulation was carried out to show thermal history and solidifica-
tion process of the plate using ANSYS software.
It was found that changes of chemical composition and changes Shrinkage porosity (depth in Hole1- 6.9 mm,
of mechanical properties in places with a long solidification time mm) Hole2- 5.6 mm
corresponding to them [10]. The formation of segregations and Hole3- 4.5 mm
shrinkage microporosity was analyzed on a riser of diameter Average hole depth = 5.66 mm
Weight (Kg) 790.4 Kg (Average weight- five trial)
1600 mm from a steel casting, obtaining the data about the segre-
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B. Tadele Bekele, J Bhaskaran, S. Dufera Tolcha et al. Materials Today: Proceedings 59 (2022) 598–604

Table 2 3.2. Materials

Details of sprocket gears for sand casting.

S. Product Dimension Input materials and equipment used during the practical test
No are shown in Table 2 below
(a) Do = 1160 mm
Dsh = 300 mm
4. Simulation analysis
Thickness = 250 mm
No of teeth = 12
Sprocket Pitch = 300 The existing casting process was simulated to form sure the
Core print = 50 mm matter with the exciting casting process. The simulation was made
Machining allowance = 10 mm by taking the prevailing parameters mentioned above. A 3D model
was prepared by using CATIA software; PROCAST software was
gear pattern
used for validating the prevailing process. As are often seen in
(b) Material Composition
Cast steel C = max 0.19, Mn = 0.40 up to Fig. 1 (a), while locating the riser, its center shifted from the mid-
0.80, Si = 0.20 up to 0.45, point of the hub, ignored by the core print of the pattern, which
P = max 0.040, S = max 0.040, was the very small riser neck height
Pouring temp = 1560 °C
(c) Method Type and amount
Sand New Silica sand (GFN 38.07 & 4.1. Simulation analysis of existing casting process
2304 Kg)
Resin Furfuryl alcohol (27.648 ml) Fig. 2 shows the simulation result of a shrinkage porosity that
Catalyst Sulphonic acid (13.824 ml)
ranges from 6 to 93.67% at different locations of the sprocket gear
Coating material Isomol coating
Powder (additive) Dolomite powder (different colour spots including red seen in the simulation analy-
(d) Gating System Specification sis). Since the location of the shrinkage porosities is at the riser’s
4 Top Risers, with geometry location, the simulation result can confirm the actual risers in
(mm); D = 220,H = 330, use are not feeding the required amount of molten metal due to
Dn = 107,Hn = 10
1Tapered cylinder Sprue with
early solidification of the molten metal before filling the cavities,
geometry (mm); Dt = 85, resulting in shrinkage porosity (see Figs. 3–10).
Db = 70, H = 40
(2700 ) Trapezoidal Runner with 4.2. Redesign of gating system
geometry (mm); W = 65,50,
Depth = 50
10 Trapezoidal In-gate with Since the Casting process is a phase transformation process, vol-
geometry; W = 80,50 umetric shrinkage is an expected phenomenon, especially in cast-
Depth = 50,40 ing steel material. Because of the short freezing range of steel, the
1Conical Pouring cup with volumetric shrinkage is expected to occur between 4 and 7%. To
geometry;
overcome that the essential requirement of the feeding system is
Dt = 190, Db = 240, H = 170
to be

Thermally adequate: it should freeze later than the casting

section
Since the shrinkage porosity defects on the existing model are
Volumetrically adequate: to feed the required amount of feed
found at the bottom of the riser’s location, this study investigates metal
the effect of faulty gating systems that can cause an early solidifi-
Should have adequate feeding range: should cover the entire
cation of molten metal in the riser. The different possibilities can casting to eliminate centerline shrinkage.
be:

Improper size of the gating system, 4.2.1. Riser design

Sufficient size but the improper location of the riser, The first step in designing a riser is to determine the optimum
feeder size. For that, a modulus method or Chvorinov’s formula is
applied, where the solidification time of casting is proportional
to the square of the ratio of volume to the surface area of the cast-
3. Method and material ing. The type of riser to be applied is the top riser type, in the iden-
tification of the section with the largest modulus or section that
3.1. Methods solidifies last in the product, where a greater probability of shrink-
age porosity might occur is the first step. Therefore from the draw-
Simulation analysis was made for checking the basis causes for ing of the sprocket gear, the section with the largest modulus can
the occurrence of the shrinkage porosity. The primary step is to easily be identified as the hub where the transformation of the
review the prevailing gating system by preparing the 3D model molten metal consumes a longer period.
by CATIA software, and simulation was made by PROCAST soft- Re-Calculation of the modulus of the hub; Modulus is the vol-
ware, taking appropriate parameters from the foundry (see ume divided by surface area or the heat to be removed by the rate
Table 3). of removal since the hub is a hollow cylinder the modulus of a hol-
Based on the identified limitation of the prevailing gating sys- low cylinder will be; Chvorinov’s equation: [13]
tem, the gating system was redesigned, which is to be tested for V n
its effectiveness by casting simulation and casting experiments. Tst ¼ Cmð Þ ð1Þ
As
After the result of the designed gating system is understood for
its favorable outcome, a practical casting test is formed to validate Where: ðAVs Þ is the modulus (the heat to be removed by the rate
the effectiveness of the planning by controlling the opposite input of removal).
process parameters as constant as possible. ‘V’ volume of casting and As  surface area
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B. Tadele Bekele, J Bhaskaran, S. Dufera Tolcha et al. Materials Today: Proceedings 59 (2022) 598–604

Table 3
Summary of geometry of Existing and re-designed gating dimensions.

Gating system Existing Re designed

Number Geometry (mm) Number Geometry (mm)
Riser 4 D = 220 2 D = 265
Top H = 330 Top H = 400
Dn = 107 Dn = 110
Hn = 10 Hn = 50
Sprew 1 Dt = 85 1 Dt = 85
Tapered cylinder Db = 70 Tapered cylinder Db = 70
H = 40 H = 40
Runner 1 (270°) W = 65,50 1 (270°) W = 90,80
Trapezoidal Depth = 50 Trapezoidal Depth = 65
In-gate 10 W = 80,50 10 W = 90,80
Trapezoidal Depth = 50,40 Trapezoidal Depth = 65
Pouring cup 1 Dt = 190 1 Dt = 190
Conical Db = 240 Conical Db = 240
H = 170 H = 170

[Link]. Riser size [13].

ðiÞDiameteroftheriserðDr Þ ¼ 6Mr ð3Þ
(ii) Height of the riser (Hr )
Hr ¼ 1:5Dr ð4Þ
(iii) Feeding distance [13]
Assuming a 50% coverage by risers
Mean diameter ¼ Do 2þDi
Total coverage by risers= p  meandiameter  0:5
Fig. 1. 3D and the pre-cast model for the simulation.
Number of the risers = 595:03mm
265:0mm
=2.24 2 risers

Tst, is solidification time, [Link]. Feeder neck dimension [13].

Cm is mold constant DN ¼ LN þ 0:2D ð6Þ
n is constant
let LN ¼ 55mm whereDN & LN are diameter and length of neck
MC ¼ VAs ¼ t  h2t þ h ð2Þ
[Link]. Gross weight of casting (Gw ) to be poured [15].
where: Mc is the modulus of casting, t thickness & h height of the
hub ðiÞV r ¼ pr 2 h ð5Þ
Modulus of the riser can be defined as [13];
where: Vr is the volume of the riser
M r ¼ 1:2Mc ð3Þ
ðiiÞW r ¼ q  V ð6Þ
where: Mr is the modulus of casting

Fig. 2. 3D Model of the pre-cast and observation of red colour spots at riser location in the simulation analysis. (For interpretation of the references to color in this figure
legend, the reader is referred to the web version of this article.)

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B. Tadele Bekele, J Bhaskaran, S. Dufera Tolcha et al. Materials Today: Proceedings 59 (2022) 598–604

where V sh ðv olumetricshirinkageÞofsteel ¼ 7:2%Vfeed > Vshrinkage , the

riser is enough

[Link]. Pouring time [15].

p ffiffiffi
T ¼ S T  Wg ð11Þ
3

where ‘S’ (correction factor) is between (1.5–1.6), by taking the

Fig. 3. Riser geometry. average, 1:5þ1:6
2
= 1.55
And mean thickness of 250
2
¼ 125mm

[Link]. Pouring rate [15].

Wg
ðRp Þ ¼ ð12Þ
T

[Link]. Pouring cup and Sprue design [16].

h  a2
Effectivepouringheight ¼ ð13Þ
2c
Fig. 4. Proportionality of riser [13].
[Link]. Chock area [16].
Wg
ChockareaðAc Þ ¼ ð14Þ
qtcð2ghÞ2
c, (nozzle coefficient) = 0.2
Ac, Chock area
p
Ac = p4D where, Dc = 4Apc
2

Dup ¼ 1:15  Dc ð15Þ

=1.1564:51 = 74.186 mm

Fig. 5. Pouring cup and Sprue.

4.2.2. Runner and In-gate design
An in-gate and runner are passages through which molten
metal enters the mold cavity. Increasing the amount of molten
metal can also ensure the existence of a sufficient amount of mol-
ten metal in the mold cavity that will minimize the occurrence of
cavities through the solidification process. Therefore, a slight
dimensional change on the existing in-gate and runner has been
Fig. 6. Runner proportion.
made both in-depth and width.
The gating ratio chosen for steel is 1:1.5: 2: d: a: b [13]

where Wr is the weight of the riser [Link]. Runner. The criterion of efficient runner design is that the
Maximumyieldof steel selected as 0.65 runner should provide a maximum cross-sectional area from the
standpoint of pressure transfer and a minimum contact on the
WN
ðiv ÞGw ¼ ð7Þ periphery from heat transfer.
max:Yield
Areaofrunner ¼ ChockareaðAcÞ  2 ð18Þ
[Link] vol. of feed metal (Vfeed ) [14]. =0.00327m2 2 = 0.00654m2 = 65.4cm2 where the values of ‘a’,
Vfeed ¼ 0:14  Vr ð8Þ ‘b’, and‘d’ are selected as; 82.5 mm, 95 mm, and 75 mm respec-
tively. Since the geometry of the sprocket gear is circular, the
Wc
Vc ¼ ð9Þ
q
Vsh
Vshrinkage ¼ Vc  ð10Þ
100

Fig. 7. Circular runner. Fig. 8. In-gate proportions.

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B. Tadele Bekele, J Bhaskaran, S. Dufera Tolcha et al. Materials Today: Proceedings 59 (2022) 598–604

[Link]. In-gate.
Areaofin  gate ¼ ChockareaðAc Þ  1:5 ð16Þ
The depth of the in-gate is found from using the expression;
Gate thickness = 1=2local casting thickness

4.3. Simulation analysis of the redesigned gating system

Simulation of the casting process has been prepared on the

redesigned gating system. The target of this simulation is merely
Fig. 9. Redesigned Gating System Layout. for testing the size of the gating system, where the risers are to
be placed similarly to the particular casting process within the
geometry of the runner is preferred to surround the casting all over foundry. In this simulation, the effect of riser location (the two dif-
the in-gates that can assure the uniform flow of the molten metal ferent locations in redesign) has been tested by placing the both on
in the mold cavity. the middle and shifting from the middle of the in-gates.

Fig. 10. 3D-CATIA and the pre-cast model of the simulation with a redesigned gating system with different riser locations (a) placed at ribs (b) between ribs (c) Pre cast
model.

Fig. 11. (a) Details of the percentage of the shrinkage porosity when the riser is placed at the ribs. (b) Details of the percentage of the shrinkage porosity when the riser is
placed between the ribs.

Fig. 11 (continued)

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B. Tadele Bekele, J Bhaskaran, S. Dufera Tolcha et al. Materials Today: Proceedings 59 (2022) 598–604

4.3.1. Simulation on the orientation of the riser 5. Conclusion

The problem of the actual riser isn’t only on the planning but
also on the positioning; i.e due to improper riser neck height, the The experiment has shown the root cause for the occurrence of
middle of the riser is shifted from the midpoint of the hub ignored shrinkage porosities was due to improper design. In general, the
by the core print. Due to these reasons, the height of the riser neck size and location of the riser are both found to be the root causes
is increased, which may allow the positioning of the center of the for the occurrence of the shrinkage porosities on the sprocket gear.
riser to get on the midpoint of the hub, minimizing the flow distur- Some the following point summarizes the result obtained in the
bance of molten metal from the reservoir to the mould cavities. simulation and experiments:
Furthermore, the solidification process of the casting was tested
by placing the risers both in between and on the ribs.
Casting simulations was helpful especially for testing the effi-
Shrinkage porosity: this defect is displayed in a percentage ciency of the gating system, minimizing the number of cast
where 100% means there is a hollow cavity, which is indicated in products through many trial and errors.
red color. While 0% means the product is totally solid in that loca-
As it observed from the simulation result, an increase in the
tion, indicated in purple color, where shrinkage porosity with a height of a riser neck assures its placement at the midpoint of
depth of between 100% and 0% are indicated with different colors. the hub that can increase its capability to properly feed into
From the simulation result shown in Fig. 11(a) and (b), it can be the right location of the cavities.
observed that the shrinkage porosity occurred from 6 to 13% at dif-
Even though an improvement was found with this experimental
ferent locations, with an improvement of 87% from 53 % from the study, more improvement can be achieved if the height of the
first simulation result with four risers (before redesign). The simu- riser neck can be increased to 50 mm, above the height of the
lation result shows a comparison on placing the risers in between core print.
and at the ribs, on both simulations, the shrinkage porosity has
Weight of the redesigned casting is more than 16 kg in average
occurred in between 6 and 13% without regarding the riser posi- (Five trials) when compared to the previous, which means that
tion. In addition to that analysis confirms that the size, locating shrinkage cavity is minimized by proper location of riser. Feed-
the riser at the midpoint of the hub and height of the riser neck ing location and feed volume is important requirements of riser
can minimize the occurrence of shrinkage porosity to a larger in sound casting
extent. Therefore increasing the height of the riser neck can ensure
the appropriate flow of molten metal from the riser to the appro-
priate location of the cavity, with improved directional Declaration of Competing Interest
solidification.
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
4.4. Experimental analysis to influence the work reported in this paper.

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