Simulation-based optimization of molten pool position in sand casting of a complex steering knuckle geometry

Abstract

This study presents a simulation-driven approach to optimizing the sand casting process for an industrial component with complex geometry, e.g., a steering knuckle used in vehicle suspension and steering systems. The geometric complexity of the component, which varies by vehicle design, poses significant challenges in achieving defect-free castings. Using advanced casting simulation software, the process was analyzed under various conditions to determine the optimal molten pool position. The evaluation criteria focused on minimizing thermal stresses and reducing casting defects such as air entrapment. Results highlight the influence of pouring direction on defect formation and thermal distribution, offering practical insights for improving casting quality and structural integrity in complex automotive components. According to the findings of this study, it is concluded that by choosing the right location for pouring the melt, the maximum thermal stress in the desired steering knuckle can be reduced by 10 MPa. In addition, the component is produced in a defect-free state or with a defect size that is so small that it can be ignored.