Designing-in controlled filling using numerical simulation for gravity sand casting of aluminium alloys

The requirements of a good running system are briefly outlined. These include classical components such as the pouring basin, downsprue, runner and gating system. Even so, it is noted that putting everything together and achieving a good working solution at the 'junctions' between these features remains a challenge. Some recent results are presented of exploratory designs for the sprue/runner junction. Both good and bad findings are described.