The document discusses the design of gating systems for metal casting. It covers determining the type of pouring basin, calculating choke area and sprue dimensions, avoiding aspiration effects which require sprue tapering, calculating filling time using Bernoulli's equation, the effects of abrupt changes and pressure on flow velocity, and considerations for pressurized versus unpressurized systems like proper gating ratios and avoiding hot spots at gate junctions.
The document discusses the design of gating systems for metal casting. It covers determining the type of pouring basin, calculating choke area and sprue dimensions, avoiding aspiration effects which require sprue tapering, calculating filling time using Bernoulli's equation, the effects of abrupt changes and pressure on flow velocity, and considerations for pressurized versus unpressurized systems like proper gating ratios and avoiding hot spots at gate junctions.
The document discusses the design of gating systems for metal casting. It covers determining the type of pouring basin, calculating choke area and sprue dimensions, avoiding aspiration effects which require sprue tapering, calculating filling time using Bernoulli's equation, the effects of abrupt changes and pressure on flow velocity, and considerations for pressurized versus unpressurized systems like proper gating ratios and avoiding hot spots at gate junctions.
The document discusses the design of gating systems for metal casting. It covers determining the type of pouring basin, calculating choke area and sprue dimensions, avoiding aspiration effects which require sprue tapering, calculating filling time using Bernoulli's equation, the effects of abrupt changes and pressure on flow velocity, and considerations for pressurized versus unpressurized systems like proper gating ratios and avoiding hot spots at gate junctions.
Decide on the type of pouring basin used Conical pouring cup (can be used for small casting) - hand ladle filling (50 mm above the entrance to the sprue) monograms can be used. - poured directly from furnace (usually from a height) monogram can not be used. Pouring bush/basin (for larger casting)
DESIGN OF DOWN-RUNNER OR SPRUE
1 Calculate the weight of liquid metal to be poured (includes the casting, the feeder, and all elements of gating system) 2 Choose location and design of gating system. 3 Determine/decide on total filling time of casting. Pouring time < solidification time of thinnest section of casting. Find solidification time 4 Find average filling rate in the gating system Average filling rate, Kg/s = Weight of casting/ filling time (4)
Continued 5 Velocity of flow: Al-bronze : 75 mm/s | Al-base and Mg-base alloys : 250 mm/s | Cu-base and Fe-base alloys : 500 mm/s 6 Calculate the effective metal head of casting hP = H 0.5 h12/h2 hP = metal head pressure at sprue base, H = height of sprue, h1 = height of casting above point of metal entry (or, height of casting in cope), h2 = height of casting. 7 Calculate the choke area A = W / [ tC (2ghP) ] A = choke area, W = casting weight (total, including all elements), = density of molten metal (Al-base alloys = 2500 kg/m3; Cu-, Fe-, Ni-, and Co-base alloys = 7000 kg/m3 for), C = discharge coefficient (= 0.8), g = acceleration due to gravity (=9.8 m/s2), t = pouring time, s. 8 Calculate the sprue exit area. [ Use Law of Continuity, Q = A1v1 = A2v2 ] 9 Calculate the sprue top area. [ Use Bernoullis Theorem, v2 = 2gh and then using law of continuity to obtain the equation A1 = A2 (h2/h1) ] A1 = sprue top area, A2 = sprue bottom area, h1 = distance between ladle and spure top, and h2 = distance between ladle and sprue bottom.
cause air (aspiration effect.) Thus to avoid Aspiration effect 2 should be zero. if 2 = 0 then 22 32 2 + = 2 2
(open to atm.)
Again by continuity, 2 2 = 3 3 3 2 = 3 2
2 = 3
2 + 2 =
3 = 2
(2)
32 2 32 2 + = 2 2
(3)
Now applying Bernoullis Eqn.
between point 1 and 3, 32 + 0 + 0 = 0 + 0 + 2 3 =
2 = 1
Where = 2 3
= 2
3 < 2
(4)
0.5
(to avoid aspiration)
taper is required.
from 3 and 4, 2 + 2 =
2 = 1
0.5
Where = 2
3 = 2
3 < 2
(to avoid aspiration)
taper is required.
(5)
Pouring time Top pouring method
Applying Bernoullis equation between point 1 and 3
32 + 0 + 0 = 0 + 0 + 2 32 = 2
If volume of casting is V then time for pouring
would be =
Fill time
Gate area
Abrupt Changes in Flow Channel Cross
Section
Abrupt Changes in Flow Direction
Effect of pressure head and change in gate
design on the velocity of metal flow
High frictional losses will require a greater pressure head to
maintain a given flow velocity
Application of Bernoulli's theorem to
flow from a runner at two ingates
Pressurized Versus Unpressurized
Systems This ratio, numerically expressed in the order sprue:runner:gate, defines whether a gating system is increasing in area (unpressurized) or constricting (pressurized). Common unpressurized gating ratios are 1:2:2, 1:2:4 and 1:4:4. A typical pressurized gating ratio is 4:8:3.
Comparison of flow patterns in two vertical gating systems. (a) Poorly designed system. (b) Properly designed system utilizing a tapered runner that equalizes flow through the ingates
Design of runner and gates
Design of runner and ingate. Use proper gating ratio. Avoid hot spot in the gate junction gate modulus 1/2 local casting modulus (gate thickness = 1/2 local casting thickness)
A spectrum of T-junctions, showing how some are hot,
some are cold, and some are neither
The maximum allowable gate
thickness to avoid a hot spot at the junction with the casting
