Optimizing gating systems and remelt

Using a gearbox housing as an example, a research project evaluated the energy savings possible by switching from an oil-based die-cooling technique to a water-based technology without affecting casting quality. A comprehensive design of experiments study (DOE) was conducted using casting simulation to evaluate the effect of several process parameters and gating designs. The software compared all of the calculated trial runs and showed the best solutions.

Here, simulation netted a 25% reduction in runner volume, which meant that 12% less material was needed per shot. The better design, in combination with the lower pouring weight, slashed cycle time by 8%.