Iterative Simulation for Robust Design and Process Integration of Filling and Solidification Systems in the Manufacturing of an IN718 Investment Casting Component

The design of filling and feeding systems in the investment casting process is typically carried out using fixed manufacturing parameters, without accounting for the natural variation caused by the equipment calibration and production fluctuations. In this study, the robustness of the proposed system was evaluated prior to production by predicting shrinkage porosity through iterative simulations using ProCAST. These calculations proved to be a critical factor, enabling a deeper understanding of the individual and combined effects of process variables of shrinkage formation. The insights gained from the simulations support early modifications to the system or adjustments to process parameters, both of which help reduce the risk of defects or minimize their occurrence during production. This methodology reduces trial-and-error by identifying optimal process windows that consistently yield high-quality parts.