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Home (/) » Casting Design (casting-designing- Casting Design

framework.html) » Gating Design and Analysis
Casting Designing Framework
(gating-design-analysis.html) » Gating & Optimal
(casting-designing-framework.html)
Filling Time
Solid Modeling (solid-
modeling.html)
Gating & Optimal Filling Time
Casting: Pattern, Mold and Core
The Optimal Filling Time is nothing but the time Design (casting-pattern-mold-core-
required to cast or mold a product .The e�ciency of the design.html)
casting is normally a�ected by two scenarios. Feeder Design and Analysis (feeder-
design-analysis.html)

Slow Filling : If the velocity of the �ll is very slow, it Gating Design and Analysis (gating-
leads to cold shuts and misruns. The slow �lling is design-analysis.html)
avoided because of the early freezing in thin sections
Gating System and Types (gating-
before the complete �lling.
system-types.html)

Gating Channel Layout (gating-

Fast Filling : The fast �lling is governed by the onset of channel-layout.html)
surface instability. The optimal �ling time lies in-
between this fast & slow �lling. It also depends on the Gating Element Design (gating-
following factors like: element-design.html)

Cast metal Gating Design & Mold Filling (gating-

design-mold-�lling.html)
Weight
Gating & Optimal Filling Time
Pouring temperature (gating-optimal-�lling-time.html)

Minimum section thickness. Gating Mold Filling Analysis (gating-

mold-�lling-analysis.html)
With the help of various experimental methods,

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Gating & Optimal Filling Time http://www.themetalcasting.com/gating-optimal-filling-time.html

researchers have developed di�erent empirical Gating Design Validation (gating-

equations, for determining the Optimal Filling Time for design-validation.html)
major metals.
Casting Rapid Prototyping (casting-
rapid-prototyping.html)

For example if the time "f" is expressed as a function of Castability (castability.html)

casting, weight "W" in kg, section thickness t"" in mm
and �uidity length Lf in mm. Casting Alloys (casting-alloys.html)

Casting Process (casting-

process.html)
A universal equation for �lling time can be written as:
F = K0 (Kf Lf / 1000) (Ks + Kt t / 20) (Kw W) Commercial Foundry (commercial-
Where, foundry.html)
K0 overall coe�cient,
Casting Applications (casting-
K0 overall coe�cient, applications.html)
Ks coe�cients of size
Ks coe�cients of size Foundry Equipment (foundry-
Ks coe�cients of size equipment.html)

Hobby Foundry (hobby-

foundry.html)
Let us take an example of the metal, Grey Iron. For this
particular metal the following values can be used:
K0 = 1.0,
Kf = 1.0,
Ks = 1.1 (for castings of size 100-1000mm), Market Research
Kt = 1.4 (for wall thickness up to 10 mm), Reports
Kw = 1
Market Research Reports (market-
P = 0.4.
research-reports.html)

Snapshots US Aluminium 2007

A pro�cient casting engineer can set the values of the (market-research-
coe�cients for each metal-process combination with reports.html#metals-mining)
his experience. These form an important part of the
knowledge base to become an expertise in speci�c Metals & Mining in the United
Kingdom (market-research-
castings.
reports.html#metals-mining)

The Optimal Filling Time also depends on the following Know More (Market-research-
two factors, which are explained brie�y below: reports.html)

Velocity of the Metal :

The Optimal Filling Time depends on the speed of �ow
of the molten metal. This mostly varies within the gating
channels and the mold openings. The metal will be hot
and fast at these locations and thus it leads to huge
damage if the �ow is not maintained properly. The
speed of the molten metal depends on two factors:

The metallostatic head and the ratio of cross-sections of

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Gating & Optimal Filling Time http://www.themetalcasting.com/gating-optimal-filling-time.html

sprue exit, runner(s) and ingates(s), which are referred

as the gating ratio. Thus the universally accepted fact is
that the speed of molten metal should be lower than 1
m/s for ferrous metals and 0.5 m/s for aluminum alloys.

Ratio of gating
Let us see some simple examples about the gating
ratio. Let As, Ar, Ag be the cross-sectional areas of sprue
exit, runner and ingate respectively. A system, where
the ingate area is more than the sprue exit area, is
considered so that the metal slows down which thereby
reduces the instability. The gating ratios include: 1:2:1.5
for ferrous and 1:4:4 for non-Ferrous metals. To reduce
the speed of the molten metal, higher values of ingate
areas such as (1:4:8) can be used. Thus optimal �lling
time depends on the above-mentioned scenarios.

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