Simulation of Casting Process: A Case Study on Directional Solidification Phenomenon for Outlet Diaphragms of Iron Ore Ball Mill

In this paper, the sand-casting process was evaluated using SUTCAST simulating software and compared with practical experience for producing the alloy steel outlet diaphragms used in iron ore ball mills. In the simulation practice, the effects of the location and dimension of the risers on the directional solidification phenomenon were evaluated to minimize the shrinkage porosity formation. The simulation results showed that the use of risers in the appropriate area leads to directional solidification and eliminates the shrinkage porosities. The results of the destructive tests after casting; confirmed the removal of these defects After the use of changes obtained by SUTCAST simulation software.