Numerical Evaluation of the Impact of Riser Geometry on The Shrinkage Defects Formation in the Solidifying Castin

The work concerns of modeling the process of manufacturing machine parts by casting method. Making a casting without internal defects is a difficult task and usually requires numerous computer simulations and their experimental verification at the prototyping stage. Numerical simulations are then of priority importance in determining the appropriate parameters of the casting process and in selecting the shape of the riser for the casting fed with it. These actions are aimed at leading shrinkage defects to the riser, so that the casting remains free from this type of defects. Since shrinkage defects usually disqualify the casting from its further use, this type of research is still valid and requires further work. The paper presents the mathematical model and the results of numerical simulations of the casting solidification process obtained by using the Finite Element Method (FEM). A partial differential equation describing the course of thermal phenomena in the process of 3D casting creating was applied. This equation was supplemented with appropriate boundary and initial conditions that define the physical problem under consideration. In numerical simulations, by selecting the appropriate shape riser, an attempt was made to obtain a casting without internal defects, using a simple method of identifying their location. This is the main aim of the research as such defects in the casting disqualify it from use.