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The
pressure in the liquid metal stream should not become less than (or should not fall below) the atmospheric pressure. If it falls
Gases produced due to baking of organic compounds in the mould enter the metal stream and result in porous castings It is called the Aspiration effect
In
other words, the shape of the sprue should be exactly as that of the metal stream did you ever observe the water falling from the tap under near laminar flow? What shape it acquires? let us determine the shape of the sprue to be made in the mould to avoid the aspiration effect.
Now
Applying the Bernoullis equation to the top gating system between points 2 and 3, we obtain that
p2 m gh2 if v2 v3
3
By the above analysis, the design of sprue with straight cylindrical (uniform cross-sectional area from 2 to 3) is not acceptable. Then, what should be the shape? The shape should be as per the following equation:
A A
3
hc ht
we can see, the sprue shape is such that the cross-sectional area varies as the reciprocal of square root of ht. is difficult to produce therefore a straight tapered sprue is used.
Ideal
change in flow direction The liquid metal contracts around a sharp corner, resulting in vena contracta Provide a round to accommodate the vena contracta d/d = 1.3 or r = 0.15d d = diameter at the entrance d = runner diameter r = radius of the round at the sharp corner
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Basin
core
Bob
equations derived till now will be affected by the following. Non-uniform velocity distribution Frictional losses
Due to friction between the molten metal and mold wall Sudden change in flow direction Due to sudden expansion or contraction of flow cross-sectional area
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velocity of metal stream decreases from the centre (max) to the mould walls (zero) to account for the non-uniform velocity distribution? introducing a constant factor in the Bernoullis equation
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How
By
Accounting for frictional losses: Between the molten metal and mold wall
The
energy loss due to friction in a circular conduit (per unit mass) is Ef1 equation for Ef1 can be obtained from the theory of flow through pipes friction factor f depends on the Reynolds number
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The
The
Equivalent
(L/D) factor for the bend has to be used in the equation of E f1.
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is determined by using average flow velocity factor ef in Ef2 is obtained from graphs
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The
Modified
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