Metal casting

Gatingsystem
A GATING SYSTEM is the conduit
network through which liquid metal
enters a mold and flows to fill the enters a mold and flows to fill the
mold cavity, where the metal can
then solidify to form the desired
casting shape
.A pouring cup or a pouring basin provides an opening for the introduction of g g g
metal froma pouring device.
A sprue carries the liquid metal down to join one or more runners, which
distribute the metal throughout the mold until it can enter the casting cavity
through ingates
Pouring Basin: An enlarged portion at the top of the sprue.
S A ti l th h hi h th lt t l t t th Sprue: A vertical passageway through which the molten metal gets to the runner.
Choke: A restriction in the gating system that limits the flow rate of the molten
metal.
Runner: The passageway metal flows through to get to the gates from the sprue.
Runner Extension: Short extension of runner which goes beyond the last gate.
In-gate: a Small passage from the runner to the mold entry .
Riser: A vertical passageway which provides a source of hot metal to prevent
shrinkage in the casting shrinkage in the casting.
Desirabledesignconsiderationsforgatingsystem
Rapidmoldfilling
The design considerations are many times conflicting
p g
MinimizingTurbulence
AvoidingMoldandCoreErosion
RemovingSlag,Dross,andInclusions
PromotingFavorableThermalGradients
MaximizingYield
EconomicalGatingRemoval
Avoiding casting distortion Avoidingcastingdistortion
CompatibilityWithExistingMolding/PouringMethods
Controlled Flow Conditions ControlledFlowConditions.
Pouringtime
Thepouringtimeiscalculatedbasedontheintegratedenergybalance
equationonthebasisofunitmassflow(Bernoullisequation)
Casea:
Assumptions:
Pressureatpoint1andpoint3isequal(i.e.P3=P1) p p q
Moltenmetallevelatpoint1ismaintainedconstant.i.e.v1=0
Frictionallossesalongthemoldsurfacesareneglected.
Applying Bernoullis equation between point 1 and point 3 gives ApplyingBernoulli sequationbetweenpoint1andpoint3gives
Timetakentofillthemoldcavity, t
f
:
f
V=VolumeoftheCasting
Ag=Crosssectionalareaofthegate. g g
Careshouldbetakentoensurethatpressureanywhereinthe
liquidmetaldoesnotfallbelowatmosphericpressure.
Applying Bernoullis equation between (3) and (2) for case (a) ApplyingBernoulli sequationbetween(3)and(2)forcase(a),
Ifpressureatpoint(3)isatmospheric,P
3
=0
Then . (sincev
2
=v
3
)
Thi i t t bl i t t ( i ti Thisisnotacceptablesincegasentrapment(aspiration
effect)fromtheporousmoldintothemoltenmetalwilltake
placeduetothenegativepressureatpoint2.
Thesprue shouldbetaperedtopreventthis.
Letinthelimitingcase,p2=0.Fromthepreviousequation,
The ideal case can be obtained as follows:
Fromcontinuityequation,A
2
v
2
=A
3
v
3
Also
P
1
=p
3
=0andv
1
=0
Thelimitingconditionforpreventingaspirationeffectis
i.e.
During fluid flow the non-uniform velocity distributions can be
accounted by replacing the (velocity)
2
by
Where is the average velocity and
= 0.5 for laminar flow and
= 1 for turbulent flow
Energy loss due to friction in a circular conduit based on per unit mass, E
f
=averagevelocity,D,L=diameterandlengthoftheconduit,
f=frictionfactor.
This should be added to the energy at station (2) in the integrated energy
equation, when the flow is from station (1) to station (2).
For a smooth conduit
h
forturbulentflow,whichcanbemodifiedto
where
The frictional loss (per unit mass ) associated with sudden enlargement or
contraction in flow area
= the average velocity in the small conduit and
= friction loss factor
The integrated energy equation between (1) and (3) thus becomes
Where = average fluid velocity in the sprue.
With P
1
= p
3
and using above equations, we get
d = diameter of the sprue, l = length of the sprue (=h
2
) p , g p (
2
)
where discharge coefficient,
Pouring time (t) Pouring time (t)
The time for complete filling of the mold
Pouring Time of casting
(i) Grey cast iron. Mass less than 450 Kg
(ii) Grey cast iron, mass > 450 Kg
K =fluidity factor K fluidity factor
T = average section thickness of casting
W= mass of Cast iron
(iii) Steel casting,
(i ) Sh ll ld d d til i
K
1
= 2.08 for thinner section
= 2.67 for 10 mm < thickness < 25 mm
(iv) Shell molded ductile iron
= 2.97 for heavier casting
For further details regarding other alloys and casting shapes, Refer to ,
P.N. Rao, Manufacturing technology, Foundry, forming and welding, Vol
1 eds 3 MGH 2011 1, eds. 3, MGH, 2011.
Chokearea
Choke is the main control are which decides the metal flow in to
the mould cavity so that mould is completely filled within the
pouring time. This is the minimum area in the gating system g g g y
and can be either at the bottom of the sprue or at the in-gate.
A = Area of the choke , mm2
W = Casting Mass , kg W Casting Mass , kg
t = Pouring time, s
D = Mass density of molten metal , kg/mm
2
H = Effective metal head mm H = Effective metal head, mm
C = Efficiency factor
Effective Metal head, H
Efficiency coefficient of gatingsystem depends on the various sections
in the gating system i e C/s change in directions of flow surface in the gating system. i.e. C/s, change in directions of flow, surface
roughness, etc.
Efficiency coefficients for various types of gating systems
Typeofsystem Tapered
chokedsprue
Straight sprue
runnerchoke
Straight runner 0 90 0 73 Straightrunner
enteringrunner
0.90 0.73
Tworunnerwithmultiple
ingate no bends in runners
0.90 0.73
ingate,nobendsinrunners
Tworunnerwithmultiple
ingate,
0.85 0.70
90 bends inrunners
Gateelements Sharp Round
Loss coefficients for various gate elements
p
Sprue entryfrompouringcup 0.75 0.20
Bendofsprue intorunner 2.00 1.00
Right angle bend in runner Rightanglebendinrunner
SquareCrosssection
Roundcross section
2.00
1.50
1.50
1.00
Junction at right angles to runner 4 0 6 0 Junctionatrightanglestorunner 4.0 6.0
Junctionwith25%ormoreareareductionfromrunnerin
toingates
2.00 0.50
Runner choke when choke area is approximately one Runnerchokewhenchokeareaisapproximatelyone
thirdrunnerarea,plusbendofsprue intorunner 13.00
Lossfromwall friction
Round channel loss = 0.02 (L/D) Roundchannelloss 0.02(L/D)
Squarechannelloss=0.06(L/D)
Rectangularchannelloss=0.07(A+B)/(2AB)
whereA=onesideofrectange and
B=othersideofrectange
Gatingratio
Gating ratio is the ratio of ; Gatingratioistheratioof;
Sprue area:runnerarea:ingatearea
Twotypesofgating:
a. Nonpressurizedgatingsystem
b. Pressurizedgatingsystem
i d i Nonpressurizedgatingsystem:
Chokeatthebottomofthesprue
No pressure existing in the gating system Nopressureexistinginthegatingsystem
Reducedturbulance
Foralloysformingdross,Al.,Mg.,etc
T d f d Taperedsprue preferred
Typicalratio1:4:4
DisadvantagesofNonpressurisedgatingsystem
To be designed carefully to see that all parts flow full Tobedesignedcarefullytoseethatallpartsflowfull
Runnersarekeptinthedragandingatesinthecope
Lowyieldduetolargevolumeofmetal. y g
Pressurized gating system Pressurized gating system
Normally ingate is the choke region
Maintains a positive pressure in the entire gating system Maintains a positive pressure in the entire gating system
Metal is more turbulent
Higher casting yield due to less volume of metal in runner Higher casting yield due to less volume of metal in runner
and in-gates
Used for ferrous alloys
Typical ratio : 1:2:1
Typesofgates
Designofgatingsystemmustconsider
Easeofmoulding
Avoidturbulentflow
Preventwashingofsandfrommoldwalls
Preventaspirationofair
Preventdrossorslagenteringthemoldalong
withmoltenmetal
Variousdesignsofgatesarebeingpracticed
Parting Gates
Skin bob and relief sprues
collect dross or slag
Principles of Metal casting, R.W. Heine,
C.R. Loper, P.C. Rosenthal, Tata
McGraw Hill
Shrink bob serving dual purpose of Shrink bob serving dual purpose of
dross collector and metal reservoir
Core inserts to filter the metal or prevent
mold erosion
Principles of Metal casting, R.W. Heine, C.R. Loper, P.C. Rosenthal, Tata McGraw Hill
Bottom Gate
Branch gate used to feed a single Branch gate used to feed a single
casting at several points or a
number of individual casting
Top gates
Riser
M t i l V l t i Sh i k (%) Material VolumetricShrinkage(%)
Mediumcarbonsteel 2.53.00
1%carbonsteel 4.00
PureAluminum 6.60
Purecopper 4.92
i l GreycatIron 1.90tonegativevalues
dependingoncarbon%
Whitecastiron 4.05.0
Functions of a riser is to feed metal to the casting as it
solidifies.
Directional solidification promoted
Requirementsofagoodriser
Th h ld b ffi i t lt t l t Thereshouldbesufficientmoltenmetalto
feedthecasting.
Facilitatesdirectionalsolidification
Therisershouldsolidifyafterthecasting.
Modulusmethod
Modulus(M)istheinverseofthecooling
characteristics(i.e.surface/volumeratio).
Th l l i Thegeneralruleis,
M
R
1.2M
c R c
Divide the whole section in to simple geometrical shapes Divide the whole section in to simple geometrical shapes.
Determine the modulus of each section considering by not
considering the surface area in contact between adjacent sections
Determine the section with the most significant modulus.
Coolingcharacteristicsofacastingcanberepresented
by the ratio of bytheratioof
If this ratio of the casting is higher than riser then Ifthisratioofthecastingishigherthanriser,then
castingwillsolidifyfaster.
Chvorinovs rule Chvorinov s rule
t = solidification time s k = mold constant t
s
=solidificationtime,s,k=moldconstant
Freezing ratio X Freezingratio,X
Caines method
Riser volume determination by Caines method
Y = riser volume /casting volume
a, b, c are constants and depends on the materials
NavalResearchLaboratory
Here a shape factor is considered where the
shape factor is defined as shape factor is defined as
The length, width and thickness are computed from the
maximum dimensions of the casting section.
The shape factor replaces the freezing ratio of the caines
method.
Riser volume determination by NRL method Riser volume determination by NRL method.
Chills
Eff t f hill f di di t Effect of chills on feeding distance
Chills