Redesigning and numerical simulation of gating system to reduce cold shut defect in submersible pump part castings

Gating system design is an essential element in casting that significantly affects the melt's molten metal flow behaviour, heat transfer, and solidification. Improper gating system leads to pouring-related defects like cold shut, misrun, etc. Submersible pump-bearing block castings produced in one of the leading foundries are rejected due to a cold shut defect. It was identified that the improper gating system is the probable cause for rejection. The bearing block and the existing gating system were modelled in 3D modelling software, and the molten metal flow behaviour of casting was simulated with casting simulation software. Based on the simulation results, the existing gating system was redesigned following established empirical relations. The component with the revised gating system was analysed for flow behaviour through simulation with the software. With the revised gating system, elimination of cold shut is observed, and the revised gating design is recommended to the industry for implementation. The effectiveness of the revised gating system is also validated with pump diffuser casing, which has similar geometrical and material characteristics. The simulation results and experimental validation showed a reduction in flow and surface defects. Appropriate design of the gating system and balanced arrangement of cavities in the gating system are noted to reduce the flow and surface-related defects. It is observed that with the revised gating systems, the percentage of rejection is reduced from 28.36% to 2.34% and 23.43% to 2.45% for the bearing block and pump diffuser casing respectively.