The following case study presents improving the casting design by changing the riser size and feeder neck position through using the simulation. Riser is placed and sized to provide sufficient metal flow into the mold during solidification.

Crank shaft           

Part Name: Crankshaft
Weight:       14kg
Mold type:  Green Sand            
Material:    (A.D.I)
Austempered Ductile Iron  

Reduced production costs by:

 • Foundry scrap reduction
 • Improved soundness 
 • Remove shrinkage 


crankshaft- pre- improved     cranshaft-td-sh-niyama=real


Liquid mapping of pre and improved design generated by SUTCAST software shows insufficient feed metal from the riser (Right) and proper feeding in improved riser (Left).

Tasks taken by SUTCAST:


  • Improving the feeding task of the risers.
  • Improving the casting design by changing the riser size and feeder neck position.
  • Improving the gating design for a uniform cooling in the entire casting.


Ductile iron is exclusively useful in many automotive components, Austempered ductile iron (ADI) has been developed for crankshaft applications because it is stronger per unit weight than aluminum, highly wear resistant and easier to machine than forged steel and it has the potential for up to 45% cost savings.