American Journal of Mechanical Engineering
ISSN (Print): 2328-4102 ISSN (Online): 2328-4110 Website: Editor-in-chief: Kambiz Ebrahimi, Dr. SRINIVASA VENKATESHAPPA CHIKKOL
Open Access
Journal Browser
American Journal of Mechanical Engineering. 2014, 2(3), 93-98
DOI: 10.12691/ajme-2-3-6
Open AccessArticle

Optimal Design of Feeder for Sand Casted Steel Dumbbell: Simulation Studies for Techno-Economic Feasibility

Haider Hussain1, and A. I. Khandwawala2

1Research Scholar, Bhagwant University Ajmer (Rajasthan), India

2Ex. Professor, Mechanical Engineering Department, SGSITS, Indore, India

Pub. Date: July 27, 2014

Cite this paper:
Haider Hussain and A. I. Khandwawala. Optimal Design of Feeder for Sand Casted Steel Dumbbell: Simulation Studies for Techno-Economic Feasibility. American Journal of Mechanical Engineering. 2014; 2(3):93-98. doi: 10.12691/ajme-2-3-6


In the casting technology, defect free casting had been the primary goal since the inception of the technology. However in the present casting arena, emphasis on the precise and defect free casting has got greatly increased due to energy saving, environmental and economy considerations apart from the stringent product quality standard requirements. In order to achieve this level, computer simulation is inevitably necessary. FEM based simulation software is used to find solidification related defects specially shrinkage porosity very precisely. In the present work ANSYS, an FEM based versatile software has been used for hot spots identification in a two feeder system. The feeders have been designed and optimized. ANSYS has been used for transient thermal analysis and then optimization process has been performed. Path of two feeder optimization for steel sand casting on ANSYS have been searched. Conductive and convective heat transfer has been taken in to consideration. The whole process is performed using traditional modulus approach also. The results are compared. The comparison reveals that ANSYS optimizer provides better results for casting having two feeders. It saves material and energy thus resulting into economy and environmental benefits too. Hence it may be recommended as superior over modulus approach for two feeder system in sand casting.

feeder design optimization FEM modulus approach sand casting shrinkage porosity steel

Creative CommonsThis work is licensed under a Creative Commons Attribution 4.0 International License. To view a copy of this license, visit


[1]  Ravi B., Metal Casting-computer aided design and analysis PHI, 2005.
[2]  Jain R.K., Production Technology, Khanna Publishers, Delhi, 15th Edition Auguest, 1995
[3]  Qin Rongshan, Workshop: Heat management, Lecturer 7, Graduate Institute of Ferrous Technology, POSTECH computational metallurgy laboratory Korea, lecturer notes, seen on web in dec., 2008.
[4]  Rao S.S., Optimization; Theory and Application, Wiley Eastern Limited, 1975.
[5]  ANSYS help-Thermal Tutorial, First order optimization, ANSYS Inc.
[7]  Joshi Durgesh and Ravi B., comparison of finite element method and vector element method for casting solidification simulation, Indian Foundry Journal, 22-23. vol. 54 no. 9 September. 22-23, 2008, PP. 21-27.
[8]  Venkatesan A., Rajadurai A., Effect of Air-Gap on Casting Solidification, American Foundary Society, 2006, PP. 191-199.
[9]  Ravi B. and Srinivasan M.N., casting solidification analysis by modulus vector method, International Journal of Cast Metals Res., 1996, PP. 1-7.
[10]  Tavakoli R. And Davami P., Optimal riser design in sand casting process with evolutionary topology optimization, Struct multidisc optim, accepted on 8 June 2008, PP. 1-10.
[11]  Tavakoli Rohalla and Davami Parviz, Optimal riser design in sand casting by topology optimization with SIMP method I : Poisson approximation of nonlinear heat transfer, equation, Struct multidisc optim, accepted on 29 October 2007, Springer-Verlag. 2008, PP. 193-202.
[12]  Elizabeth Jacob, Roschen Sasikumar, B. Praveen and V. Gopalakrishna, Intelligent design of feeders for castings by augmenting CAD with genetic algorithms, Journal of Intelligent Manufacturing, 15, 2004, PP. 299-305.
[13]  P. Prabhakara Rao, G. Chakraverthi, A.C.S. Kumar, G. Srinivasa Rao, Modeling and Simulation of Solidification in Alloy Steel Sand Castings, International Journal of Thermal Technologies, Vol. 1, No. 1 Dec. 2011, PP. 121-127.
[14]  T. Nandi, R. Behera, A. Chanda and G. Sutradhar, Study on Solidification Behaviour of LM6 Castings by Using Computer-Aided Simulation Software, Indian Foundry Journal, Vol. 57, No. 3, March 2011, PP. 44-49.
[15]  Behera Rabindra, Kayal.S, Sutradhar. G, Solidification behavior and detection of Hotspots in Aluminium Alloy castings: Computer Aided Analysis and experimental validation, International Journal of Applied Engineering Research, Dindigul, Volume 1, No 4, 2011, PP. 715-726.
[16]  Belmira Neto, Carolien Kroeze, Leen Hordijk, Carlos Costad, Modelling the environmental impact of an aluminium pressure die casting plant and options for control, Environmental Modeling & Software, Volume 23, Issue 2, February 2008, PP. 147-168.