Design Optimization of Gating System by Fluid Flow and Solidification Simulation for Front Axle Housing

In spite of knowledge of conventional gating design casting defects such as shrinkage and gas porosities were found in front axle housing a critical automotive component. This component is generally made out of spheroidal graphite iron. A flawed gating system was found to be the reason for improper fluid flow and melt solidification which in turn produced casting defects. Optimization of the gating and risering system by using casting simulation software ADSTEFAN was carried out. Through several simulation iterations, it was concluded that defect free casting could be obtained by modifying the initial gating ratio 2:2:1 to 2:1.76:1. Also shifting of sprue location from centre to end and providing the risers at location prone to formation of shrinkage porosity led to the decrease in size of the shrinkage porosity about 97%. Keywords— Front Axle Housing, Casting Simulation, Gating Design Optimization, Fluid Flow and Solidification Simulation, Shrinkage Porosity.