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
:
V= Volume of the Casting V VolumeoftheCasting
Ag=Crosssectionalareaofthegate.
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 > 150 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<thickness <25
(iv) Shell molded ductile iron
= 2.97 for heavier casting