<p>3D printing has become more popular in sand casting due to its ability to create complex gating designs, allowing new opportunities to improve casting quality. Since filling related defects, like entrained air and bi-films, are most commonly caused by high velocity and turbulence, research has typically focused on designing gating systems aimed to reduce melt velocity and turbulence. Runner extensions are rarely looked at as methods of improving casting quality, despite the impact they have on the initial melt flow. 3D printed sand molds allow for unique extension designs that aid in improving casting quality. In this paper various runner extension were investigated to determine the most effective design for reducing sand casting defects. Based on concepts from previous research, six different runner extensions were created and simulated using Computational Fluid Dynamics (CFD). The designs were evaluated, examining their ability to reduce defects like entrained air and bubbles, as well as preventing backflow and reflected waves. The results showed a correlation between the ability of the runner extension to assist in controlling the initial metal flow, and the overall casting quality. These results provide a framework to further optimize runner extensions, utilize the advantages of 3D Sand-Printing technology, and improve casting quality.</p>

A Computational Study on Novel Runner Extension Designs via 3d Sand-Printing to Improve Casting Performance

Paper Proceedings: https://asmedigitalcollection.asme.org/MSEC/MSEC2021/volume/85062

2021 International Manufacturing Science and Engineering Conference (MSEC2021)

Supporting the need among researchers worldwide for additional online and multimedia content, ASME now offers the ASME Conference Video Collection. This platform will collect and provide long-term access to conference presentation videos, encompassing all technology areas within ASME's technical conference and events program. About 30,000-40,000 engineers across all mechanical engineering and related disciplines participate in ASME conferences each year. This includes authors of approximately 6,000 to 8,000 technical papers published by ASME, the majority of whom also submit video presentations for our virtual conferences. The video collection will be available as an add-on to existing product packages or as a separate subscription.