**8. Conclusions**

*Casting Processes and Modelling of Metallic Materials*

the pattern strategically.

metal to minimize heat loss.

e. Some ventings (shown by black arrow in **Figure 13(a)**) are suggested to increase permeability. In this case the mould is made using high pressure moulding so the permeability of the mould is very low, and making of manual conventional vent just before metal pouring is very tough in such cases. So while, making the mould cavity, some rods f small diameter are attached with

f. Exothermic powder is also advised to be used immediately after pouring the

**Figure 12(a)** clearly indicates that the total solidification time is 3869 seconds i.e. 958 seconds (Approximate 16 minutes) more time than the solidification time

**66**

**Figure 13.**

**Figure 12.**

*Defect analysis of the product after modifications*

*Modifications done in the existing design to obtain sound casting*

In this study, the advantages of casting simulation software, limitations, and some best practices have been observed along with some case studies to understand the process logically and scientifically. Simulation technology has appeared as a blessing to foundry engineers to implement virtual experimentations, forecast casting defects and enhance the existing casting design without melting metal in furnace. This not only reduces the expense of die modification and material/energy costs but also contributes a more beneficial insight into the process. On the other hand, with the advancement of technology, to produce zero defect castings with improved yield, it is very much required to optimize the casting design (feeding and gating). This goal can be accomplished by coupling intelligent design assistant module of simulation software. This will enable us to complete the design-simulateanalyze cycle within a time less than one hour. This tool enables us to optimize complex castings in a single day. This also assures more acceptable casting design, quicker than ever before.
