CAE software to optimize feeding system of butt-welded valve

In sand mold casting, one of the critical elements to have good results is the design of the feeding system, which must be optimized to increase the casting's yield and the foundry's process efficiency. The paper describes activities and results within a traineeship at Politecnico di Milano in collaboration with Fonderia Augusta, Fluicon Valves and Enginsoft. The case study consists in the design of a feeding system for butt-welded top entry valves for cryogenic service. Thanks to MAGMA 5, a CAE software provided by Enginsoft, the evaluation of different feeding systems and different casting's positions in the mold has been possible. At the same time the possibility to reduce valves thickness of non-standard parts has been evaluated. The simulation of three different casting configurations has allowed to define the best solution characterized by 20% casting material reduction and a significant surface defects reduction.