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Introduction
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Pouring basin:
The pouring basin or bush or cup is a circular or rectangular pocket
that accepts
the molten metal
from
the ladle;
The
members
of
the
gating
Pouring basins that contain a well deeper than their depth at the
system
sprue junction to effectively absorb the impact of the arriving
stream, and flow velocity will be governed by sprue height only;
Another advantage of this design is that pouring may start out
slowly without molten metal entering the sprue;
Once the proper location of the ladles lip has been established, fast
pour and sprue filling begins with minimum slag entry;
A liquid metal is poured in to the pouring basin ,which acts as a
reservoir from which it moves into the sprue smoothly;
Reduces turbulence and vortexing at the sprue entrance;
Helps separating dross and slag before entering to the sprue;
Pouring basin may be cut directly in to the cope portion or
separately from dry sand.
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Contd
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Contd
Sprue:
Circular cross sections are being used most commonly;
Tapering the sprue downwards is always a good practice;
Straight or nearly straight sprue may be used in all pressurized
systems;
Chocked at the bottom (or sprue basin) of the sprue must be used in a
non-pressurized gating systems.
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Contd
Runner.
A straight runner is the best choice of space permits it. If bending the
runner is unavoidable, it should be done with as large radius as space
permits, because curvatures introduce additional turbulence;
A minimum distance of 50 mm between the end point of the runner
and the next gate us recommended;
The cross section of the runner is almost always rectangular with
thickness to height ratio of 1:2 in a pressurized system.
The runner system is fed by the well and is the path that the gates are
fed from;
The Runner path should promote smooth laminar flow by a balanced
volumetric flow, and avoiding sharp or abrupt changes in direction;
The "Runner Extension" is a "Dead-End" that is placed after the last
gate;
The R-Ext acts as a cushion to absorb the forward momentum or
kinetic energy of the fluid flow. The R-Ext also acts as a "Dross/Gas
Trap" for any materials generated and picked-up along the flow of
the runner.
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Contd
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Runner-gate Junction
A gate must never be placed in straight continuation of the
runner;
Gates must branch off the side(s) of the runner at near
right of the runner, which forms a relationship to the
choke or base of the sprue area;
The issue of sharp corners (both inner and outer) create
turbulence, low & high pressure zones that promote
aspiration of mold gases into the flow, and can draw mold
material (sand) into the flow;
None of this is good, by providing curved radius changes
in direction the above effects are still at play but at a
reduced level. Similarly sharp angles impact the
solidification process and may inhibit "Directional
Solidification" with cross-sectional freezing.
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Gate-Casting junction
The gates need to join the thinnest sections of the casting
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Contd
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Contd
Bottom gating systems: have the opposite characteristics:
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Contd
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Contd
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Contd
Better separation of slag, the metal enters the mold cavity with
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Gating ratio
Gating Ratio is given by As:Ar:Ag where As , Ar , Ag are
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Law of Continuity
The law of continuity states that the flow rate must be the
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Bernoullis Theorem
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Contd
As mentioned earlier, Bernoullis theorem can only be
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Reynold's Number
Nature of flow in the gating system can be established by
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Contd
When the Reynold's number is less than 2000 stream line
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Contd
Re is usually between 2000 and 20000
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Fluidity
Fluidity is capability of the molten metal to fill the mold
cavities;
Gating system design strongly depends on knowledge of
fluid flow;
A measure of the capability of a metal to flow into and fill
the mold before freezing. (Inverse of viscosity);
Factors affecting fluidity:
Viscosity: Increasing viscosity and sensitivity to temperature
reduces fluidity;
Surface tension: High surface tension reduces fluidity;
Inclusions: Insoluble particles reduce fluidity;
Pouring temperature, Metal composition, Heat transfer to
the surroundings, Heat of fusion and Solidification are the
factors;
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Pouring Time
For determination of pouring time, the following
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Contd
Pouring cup
Cut into cope
Large enough to keep the sprue full
Skim core to provide clean metal
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Choke Area
The gating system can be designed to fill a given casting
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Where: Ac=choke
area, mm2;
W= casting mass including gating elements, kg ;
= mass density of molten metal, kg/mm3;
g= acceleration due to gravity, mm/s2=980mm/s2 ;
C= efficiency factor which is a function of gating
system use=0.9 for single runner;
H=effective sprue height
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Design of Sprue
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Risering:
Risers are reservoirs of molten metal that are used to feed
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Risers Rule
1. Risers are located near thick sections of the casting;
2. Side risers are usually located on top of the gates. Use of side
risers is common for thin-walled castings. Since the first metal to
enter the casting will warm the bottom of the side riser and cool
down, and side risers will be filled with hot metal, use of side
risers promotes sequential solidification;
3. Top risers are located on bosses, away from the gates;
4. If the casting is bottom-gated, fast filling of the mold with more
gates, use of insulated or exothermic risers, and chilling the gate
area are safe practices to cure unfavorable temperature gradients.
In the case of open risers, hot metal can also be poured into the
riser after solidification starts;
5. Risers are sized by the volume fed. In the case of multiple
risering, each riser is considered to be feeding a part of the
casting and is sized according to the volume of that part in
question;
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Contd
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Types of Risers
Open and Closed (according to form of construction);
Direct ,which connected as a rule at the upper surface of
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Contd
Cutting or easily removable (according to method of
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Risering design
Risering is a process designed to prevent shrinkage voids
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Contd
Vriser V part
Or, assuming that a cylindrical riser is used,
A part
r 2 2rh
V part
r 2 h
rh
V par
or
A part
1
2
h
r
V part
The height obtained using the Equations above is usually multiplied with a factor of
safety of about 1.2 on parts that have cylindrical bosses, the radius of the riser
selected is slightly less than that of the boss to ease the removal of the riser from the
part after solidification.
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Where 'a' is
the ratio of the riser volume to casting volume
Contd
Naval research method is essentially a simplification of
the chain's method, defines a shape factor to replace the
freezing ratio.
The shape factor is deified as:
Using naval research method of the graph, determine the
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