Design and Development of an Offline-Capable AI Tool for Gating System Calculation in Foundries

This paper presented Vishvakarma Foundry AI, an AI-assisted and offline-capable framework for preliminary gating and riser design in sand casting. The work combines geometry-based volume estimation, Bernoulli-based gate-area calculation, gating-ratio rules, riser estimation, web-backend implementation, chatbot explanation, clipboard fallback and a microcontroller-based display prototype. The manual QA workbook demonstrates the repeated calculation structure across a wide range of components, while the time comparison indicates a substantial reduction in preliminary design effort for supported cases. The proposed framework fills an accessibility gap between slow manual calculation and advanced simulation software. Its most appropriate use is as a first-pass engineering assistant for students, MSME foundries and early design screening, followed by expert review, simulation and casting trials for production-critical parts.

[1] M. Iqbal, “Gating design criteria for sound casting,” International Journal of Mechanical Engineering and Robotics Research, vol. 3, no. 3, pp. 675-694, 2014. [2] J. Jezierski, R. Dojka and K. Janerka, “Optimizing the gating system for steel castings,” Metals, vol. 8, no. 4, Article 266, 2018. [3] A. P. Edlabadkar et al., “Empirical exploration of optimal gating system design for sand casting process,” African Journal of Applied Research, vol. 11, no. 1, pp. 871-891, 2025. [4] J. Campbell, Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design, 2nd ed., Butterworth-Heinemann, 2015. [5] P. Beeley, Foundry Technology, 2nd ed., Butterworth-Heinemann, 2001. [6] R. Kumar et al., “Casting design and simulation of gating system in rotary adaptor using ProCAST software for defect minimization,” Materials Today: Proceedings, 2020. [7] Project document, “Detailed Comparison: Research Papers vs Vishvakarma Foundry AI,” uploaded project literature comparison file, 2026. [8] Project document, “Manual Calculation for QA,” handwritten calculation workbook for 50 casting components, 2026. [9] Project document, “Gemini API Integration System Project Report,” backend usage information file, 2026. [10] Project document, “Frontend Design Drawings,” pattern-configuration and live-preview sketches, 2026. [11] Project document, “Revenue Generation & Spending,” business model and deployment assumptions, 2026.