In spite of knowledge of conventional gating design casting defects such as shrinkage and gas porosities were
found in front axle housing a critical automotive component. This component is generally made out of spheroidal graphite
iron. A flawed gating system was found to be the reason for improper fluid flow and melt solidification which in turn
produced casting defects. Optimization of the gating and risering system by using casting simulation software ADSTEFAN
was carried out. Through several simulation iterations, it was concluded that defect free casting could be obtained by
modifying the initial gating ratio 2:2:1 to 2:1.76:1. Also shifting of sprue location from centre to end and providing the
risers at location prone to formation of shrinkage porosity led to the decrease in size of the shrinkage porosity about 97%