Automatic Optimization of Casting Feeders Using Feed-Paths Generated by VEM

Feeding or risering system of a casting significantly affects the internal quality as well as the yield of a casting. It is however, quite difficult to predict the effect of a particular set of feeder design parameters (such as location, shape and dimensions) on casting quality. Hence feeding system design is iterative in practice, involving tooling modification, foundry trials and inspection. Computer simulation can save material and production resources involved in foundry trials, but requires a higher level of human effort for preparing the inputs and interpreting the results properly. In this work, we have evolved a new approach to evaluate and optimize casting feeding system design using feed-paths. The feed-paths are computed by Vector Element Method (VEM). It is possible to automatically track the direction of the feed metal flow from a given point, and to check if a feeder is effective. The convergence of the feed-paths provides a clear indication of directional solidification and location of shrinkage defects. Further, this takes a fraction of the time taken by FEM-based simulation, making it more useful for practical application. The proposed approach is demonstrated by automatically optimizing the feeder size for a benchmark casting, and validated by pouring and sectioning Al-alloy castings made in sand molds.