Modifying the Gating System of the Bracket Torque Rod

Abstract

Sand casting is one of the most widely used manufacturing processes for producing complex metal components in the automotive and industrial sectors. However, improper gating system design can lead to casting defects such as turbulence, porosity, misruns, and uneven solidification. This study focuses on modifying and optimizing the gating system used in the sand casting of a bracket torque rod to improve casting quality and manufacturing efficiency. The existing gating design was analyzed to identify issues related to turbulent metal flow and improper mold filling. Engineering design principles and casting calculations were applied to redesign the sprue, runner, and gate dimensions to ensure smooth metal flow and controlled solidification. Simulation and analysis were conducted to evaluate the performance of the modified design. The results indicate improved mold filling behavior, reduction in casting defects, and better casting yield compared to the existing gating system. The optimized gating system provides improved reliability and efficiency in the production of automotive casting components.