ADVANCEMENTS IN GATING SYSTEM DESIGN FOR GREEN SAND CASTING: A COMPREHENSIVE REVIEW FOR INDUSTRY 4.0 INTEGRATION

Green sand moulding continues to dominate global foundry practices, contributing to nearly 70% of metal casting production due to its cost-effectiveness and versatility. However, casting quality is critically dependent on gating system design, with poor layouts responsible for up to 90% of common defects such as porosity, cold shuts, shrinkage, and inclusions. Traditional design approaches—largely empirical and trial-based—often result in suboptimal quality, material wastage, and extended product development cycles. This review consolidates current research on systematic gating system design, tracing the evolution from conventional methodologies to advanced computational and data-driven approaches. Emphasis is placed on the role of Computational Fluid Dynamics (CFD) and casting simulation tools (e.g., MAGMASOFT, ProCAST, AutoCAST-X1) in predicting fluid flow, solidification, and defect formation with high accuracy. Furthermore, the paper highlights the transformative impact of Industry 4.0 technologies, including IoT-enabled sensor networks, machine learning-driven defect prediction, and digital twin-based real-time optimization. Despite these advancements, gaps remain in multi-objective optimization frameworks, integration of artificial intelligence for holistic gating design, and the adaptation of additive manufacturing for complex gating geometries. This comprehensive review not only synthesizes existing knowledge but also identifies future research directions toward achieving defect-free, high-yield, and sustainable casting practices. Keywords: Green sand casting, gating system, CFD simulation, Industry 4.0, digital twin, defect reduction, optimization.