International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 13 Issue: 06 | Jun 2026
p-ISSN: 2395-0072
www.irjet.net
An MSME Foundry Improvement Framework Integrating SimulationBased Gating System Optimization for Defect Reduction and Production Efficiency Enhancement Jay Dabhi1, Dr. Ashishkumar V. Gohil2 1Ph.D. Research Scholar, Mechanical Engineering, Lukhdhirji Engineering College, Morbi, Gujarat Technological
University, Ahmedabad, Gujarat, India.
2Professor and Head of Department, Production Engineering, Lukhdhirji Engineering College, Morbi, Gujarat
Technological University, Ahmedabad, Gujarat, India. ---------------------------------------------------------------------***--------------------------------------------------------------------1. INTRODUCTION Abstract - Micro, Small and Medium Enterprise (MSME) foundries are important contributors to the manufacturing industry, as they make a variety of engineering parts with the sand-casting process. But a lot of MSME foundries are suffering from serious issues like rejection rate, casting defects and lack of modern manufacturing technologies. Many of these problems occur because the gating system design is incorrect, the process does not involve simulations to analyze the process, and the personnel are not aware of the principles of defect prevention and optimization of production. This research provides a detailed experimental and numerical simulation study of an existing sand-casting gating system, with a view to geometrical optimization. The casting process was simulated in the ProCAST software to determine the filling behavior, solidification characteristics, temperature distribution during mould filling, formation of shrinkage porosity, time to solidus and prediction of voids. The simulated geometry of the gating system was optimized based on the analysis results to optimize the molten metal flow and to improve the geometry for the directional solidification. The optimized gating system was tested in the experimental study of an MSME foundry under industry standard conditions and limitations such as limited technological resources and traditional manufacturing practices. The obtained results showed that the casting defect has been improved significantly as well as the casting yield and production efficiency. This research also explores the operational issues encountered by the MSME foundry personnel including pattern makers, moulders, grinders, welders and machines. On-site observations and interviews with workers were conducted to develop practical recommendations for enhancing worker skills, practices and process knowledge. In addition, a MSME Foundry Improvement Framework Model is developed to incorporate simulation-based process optimization and workforce development and operational improvements. The suggested framework offers a realistic approach for MSME foundries to boost productivity and quality of products under resource constraints.
Sand casting is still one of the most popular casting methods because it can be used to make complex metal parts at a relatively low cost. The casting system (gating and feeding system) which regulates the flow of molten metal to the mould cavity, plays an important role in the quality of sand castings. If the casting gating system design is incorrect, it can cause problems in the casting, including the shrinkage porosity, air entrapment, incomplete filling, and formation of voids. The problems are more common in MSME foundries where the casting design and casting production process are more traditional than scientific analysis. There are also challenges with limited access to advanced manufacturing technologies, the absence of simulation tools and inadequate technical training, which lead to production inefficiencies. Advances in casting simulation technology have made it possible for engineers to study the behavior of molten metal flow, heat transfer and solidification of the metal prior to casting production. ProCAST simulation software offers a great tool for predicting casting defects and gating system design optimization. However, in spite of these technology developments, the use of simulation-based optimization techniques in foundries of MSME is still in its infancy because of financial constraints, technical awareness and exposure to the modern manufacturing techniques. Thus, research combining simulation-based casting optimization and practical industrial validations and workforce-based improvements is needed. This is addressed by the present research which is undertaken through geometry optimization of the existing gating system using numerical simulation and validated in the foundry environment of MSME. Further, operational issues encountered by the shop floor workers are studied and a holistic framework for MSME improvement is suggested to improve the overall performance in production.
2. LITERATURE REVIEW
Key Words: Numerical Simulation; ProCAST; MSME Foundry Improvement Framework; Casting Defects; Shrinkage Porosity Analysis; Industrial Validation; Production Efficiency; Small-Scale Foundry.
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The gating system is one of the key factors that influence the quality, reliability and productivity of metal casting process. The gating system determines the flow of molten metal in the mould cavity and has a significant effect on
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