**Figure 12.**

*Defect analysis of the product after modifications*

**67**

*Simulation and Validation of Castings in Shop Floor DOI: http://dx.doi.org/10.5772/intechopen.94596*

component.

**8. Conclusions**

quicker than ever before.

**Acknowledgements**

present shape.

**Conflict of interest**

The authors declare no conflict of interest.

consumed before modification. Liquid state simulation of **Figure 12(b)** shows that a smooth directional solidification has been achieved and all major hot spots have been eliminated from the cast components. **Figure 12(c-d)** indicates occurrence of minor shrinkage defect in the casting but these are not detrimental to the

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,

Authors wish to convey their heartfelt thanks to Mr. Prashant K, Senior Ex-Application Manager, DHIO research and engineering private limited for his support in while making the Z-Cast simulations for this case study. The authors are also indebted to D N Ganesh Babu, General Manager, Product Sales & Services, DHIO Research & Engineering Pvt. Ltd. for his continuous support for giving the Z-Cast software. Author also thankfully acknowledge the contribution of Mr. Abresh Ranjan Das for his continuous support & help for sharing his profound experiences to complete this work unless otherwise this work could not get the

**Figure 13.** *Modifications done in the existing design to obtain sound casting*

consumed before modification. Liquid state simulation of **Figure 12(b)** shows that a smooth directional solidification has been achieved and all major hot spots have been eliminated from the cast components. **Figure 12(c-d)** indicates occurrence of minor shrinkage defect in the casting but these are not detrimental to the component.
