Scribd Logo
Upload

Welcome to Scribd!

  • 55 views

    Design of Gating and Feeding Systems-2

    Uploaded by

    kaushikb26
    This document provides guidelines for designing a gating system for metal casting. It discusses: 1) Choosing between a conical pouring cup or pouring bush based on the size of the casting and filling method. 2) Calculating filling time, average filling rate, choke area, and sprue dimensions based on casting weight, material properties, and pouring conditions. 3) Designing runners and ingates with proper dimensions and ratios to avoid hot spots. 4) Using inclusion controls like filters or traps to prevent sand and oxides from entering the mold cavity.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Design of Gating and Feeding Systems-2

    Uploaded by

    kaushikb26
    55 views1 page
    This document provides guidelines for designing a gating system for metal casting. It discusses: 1) Choosing between a conical pouring cup or pouring bush based on the size of the casting and filling method. 2) Calculating filling time, average filling rate, choke area, and sprue dimensions based on casting weight, material properties, and pouring conditions. 3) Designing runners and ingates with proper dimensions and ratios to avoid hot spots. 4) Using inclusion controls like filters or traps to prevent sand and oxides from entering the mold cavity.

    Original Title

    Design_of_Gating_and_Feeding_Systems-2

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides guidelines for designing a gating system for metal casting. It discusses: 1) Choosing between a conical pouring cup or pouring bush based on the size of the casting and filling method. 2) Calculating filling time, average filling rate, choke area, and sprue dimensions based on casting weight, material properties, and pouring conditions. 3) Designing runners and ingates with proper dimensions and ratios to avoid hot spots. 4) Using inclusion controls like filters or traps to prevent sand and oxides from entering the mold cavity.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    55 views1 page

    Design of Gating and Feeding Systems-2

    Uploaded by

    kaushikb26
    This document provides guidelines for designing a gating system for metal casting. It discusses: 1) Choosing between a conical pouring cup or pouring bush based on the size of the casting and filling method. 2) Calculating filling time, average filling rate, choke area, and sprue dimensions based on casting weight, material properties, and pouring conditions. 3) Designing runners and ingates with proper dimensions and ratios to avoid hot spots. 4) Using inclusion controls like filters or traps to prevent sand and oxides from entering the mold cavity.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 1

    DESIGN OF GATING SYSTEM

    1. DESIGN OF POURING BUSH/BASIN


    Decide on the type of pouring basin used, Fig. 6:
    x 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.
    x Pouring bush/basin (for larger casting)

    2. DESIGN OF DOWN-RUNNER OR SPRUE


    2.1 Calculate the weight of liquid metal to be poured (includes the casting, the feeder, and all elements of
    gating system)
    2.2 Choose location and design of gating system.
    2.3 Determine/decide on total filling time of casting. See Appendix 1 and Appendix 2.
    Pouring time < solidification time of thinnest section of casting. Find solidification time from modulus
    or use Fig.4. Experience / trial and error are needed.
    2.4 Find average filling rate in the gating system
    Average filling rate, Kg/s = Weight of casting/ filling time (4)
    2.5 Select the 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
    2.6 Calculate the effective metal head of casting
    hP = H – 0.5 h12/h2 (5)
    hP = metal head pressure at sprue base, H = height of sprue, h1 = height of casting above point of
    metal entry into the mould (or, height of casting in cope), h2 = height of casting.
    2.7 Calculate the choke area
    A = W / [ UtC — (2ghP) ] (6)
    A = choke area, W = casting weight (total, including all elements), U = density of molten metal (Al-base
    alloys = 2500 kg/m3; Cu-, Fe-, Ni-, and Co-base alloys = 7000 kg/m3 for), hP = effective height of
    metal head, C = discharge coefficient (= 0.8), g = acceleration due to gravity (=9.8 m/s2), t = pouring
    time, s.
    2.8 Calculate the sprue exit area. [ Use Law of Continuity, Q = A1v1 = A2v2 ]
    2.9 Calculate the sprue top area. [ Use Bernoulli’s 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.
    2.10 Design of sprue base (or, well).

    3. DESIGN OF RUNNER AND GATES


    3.1 Design of runner and ingate. Use proper gating ratio. See Fig. 7.
    Avoid hot spot in the gate junction gate modulus | 1/2 local casting modulus. See Fig. 8.
    ( Ÿ gate thickness = 1/2 local casting thickness)
    3.2

    4. INCLUSIONS CONTROL
    Use one or more inclusion control systems (Filters, dross trap or swirl trap) in the gating system to
    avoid entry of sand, oxide film and other inclusions into the mould cavity.

    MME346/Expt #06A/Page 2 of 12

    You might also like