PSI - Issue 79

Available online at www.sciencedirect.com

ScienceDirect

Procedia Structural Integrity 79 (2026) 65–72

© 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of IGF28 - MedFract3 organizers Keywords: Sand casting process; Casting simulation; Molten pool position; Thermal stress; Casting defects; Air bubbles. 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. 1. Introduction Sand casting remains one of the most widely employed manufacturing techniques for producing complex metal components due to its versatility, cost-effectiveness, and ability to handle large geometries [1]. Despite its advantages, minimizing defects such as porosity, shrinkage cavities, and thermal stresses continue to challenge foundry engineers, especially in the case of complex geometric components [2, 3]. However, in the automotive industry, different casting methods are used to produce different parts [1, 4]. For example, one of these vital and common components between 28th International Conference on Fracture and Structural Integrity - 3rd Mediterranean Conference on Fracture and Structural Integrity Simulation-based optimization of molten pool position in sand casting of a complex steering knuckle geometry Kazem Reza Kashyzadeh a,* , Negewo Getu Bogale a a Department of Transport Equipment and Technology, Academy of Engineering, RUDN University, 6 Miklukho-Maklaya St., Moscow 117198, Russian Federation.

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of IGF28 - MedFract3 organizers 10.1016/j.prostr.2025.12.308