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Gating System:
Components
a. Pouring basin
b. Sprue/Down runner
c. Runner
d. Gates
e. Risers
Gating system
Rate of pouring
Fluidity of metal
Size and type of gates
Size and type of sprue/runner
Type of pouring equipment
(a)
(b)
1.
2.
3.
4.
5.
Velocity
is
high,
severe Velocity is low and turbulence is
turbulence may occur at corners. reduced.
Improvised Design
Oxidation of metal
Cold shuts
Mould erosion
Shrinkages
Porosity
Misruns
Penetration of liquid metal into mould walls.
Using the convention that the head is measured relative to the Efflux
point, then
h3 = 0. Assuming that the system is operating in normal conditions
of 1 atmosphere P1=P3.
Finally the assumption is always made that the pouring basin
remains full so that at point 1, v1 = 0 in / sec. Therefore Bernoullis
Law reduces for points 1 and 3 to:
Pouring Time to fill the mould cavity = v/Q
Where v= Volume of mould cavity
Q = Volume flow rate
Problems
1. The sprue leading into the runner of a certain mold has a length =
175 mm. The cross-sectional area at the base of the sprue is 400
mm2. The mold cavity has a volume = 0.001 m3. Determine (a) the
velocity of the molten metal flowing through the base of the
downsprue, (b) the volume rate of flow, and (c) the time required
to fill the mold cavity.
Solution:
(a) Velocity V = (2 x 9815 x 175)0.5
= (3,435,096)0.5 = 1853 mm/s
(b) Volume flow rate Q = VA
= 1853 x 400 = 741,200 mm3/s
(c) Time to fill cavity TMF = v/Q
= 1,000,000/741,200 = 1.35 s
3. Molten metal can be poured into the pouring cup of a sand mold at a
steady rate of 1000 cm3/s. The molten metal overflows the pouring
cup and flows into the downsprue. The cross section of the sprue is
circular, with a diameter at the top = 3.4 cm. If the sprue is 25 cm
long, determine the proper diameter at its base so as to maintain the
same volume flow rate.
Solution:
Velocity at base v = (2gh)0.5 = (2 x 981 x 25)0.5 = 221.5 cm/s
Assuming volumetric continuity,
area at base A = (1000 cm3 /s)/(221.5 cm/s)
= 4.51 cm2
Area of sprue A = D2/4
D2 = 4A/ = 4(4.51)/ = 5.74 cm2
D= 2.39 cm
Riser
To prevent cavities/voids due to shrinkage
To provide molten metal to the casting as
it solidifies
R > t C
where t R and t C is the Solidification time
for Riser and Casting according to
Chvonirovs Rule
Solidification Time
Solidification takes time
Total solidification time TST = time required for
casting to solidify after pouring
TST depends on size and shape of casting by
relationship known as Chvorinov's Rule
Is a function of the volume of the casting and its
surface area
Volume
Time C
Surface Area
Where
C constant (mold material, metal property, temperature)
n 2
EXAMPLE
5 cm
10 cm
15 cm
A
cylindrical
riser
with
dimensions of D=h must be
designed.
Previous
observations
show
tcasting=1.6
min.
for
casting.
Determine
dimension of riser.
triser=2 min.
2
Soln:
t Cm (V A) n
Vr
D h
D3
2 2 6 2
D
D
4
4
Vr
4 D3 D
2
Ar 6 4 D
6
Ar Dh
Vc 15 10 5 750cm3
Ac 2(15 10 15 5 10 5) 550cm 2
1.6 Cm (750 550) 2
Cm 0.86 min cm 2
2 0.86( D 6) 2
D 9.15cm
h 9.15cm