Gating and risering Tesfaye Girma riseringby

BAHIR DAR UNIVERSITY

(IOT) SCHOOL OF MECHANICAL AND INDUSTRIALENGINEERING,
MSC PROGRAM IN MANUFACTURING ENGINEERING
ADVANCED FOUNDRY TERM PAPER

BY TESFAYE GIRMA ALEMAYEHU

ID-Msc/00036/04 ID

SUBMITTED TO;-PROF.RATINAM UPPAL PROF.RATINAM

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Gating and riseringby Tesfaye Girma

Abstract The design of gating and rise ring, or rigging systems as they are sometimes referred to, has been a very important task in the manufacture of cast components. This paper presents a compilation of common rules of thumb used by foundry experts and guidelines suggested by researchers for better quality castings. The paper is divided into three sections: light alloy, steel and ductile iron castings. Each section presents heuristics com-monly used for specific metals.

Gating and riseringby Tesfaye Girma

Acknowledgement In the world there is no one absolute in his work .I thought from the world so much, the world teaches me so much .I give my gratitude thanks for those who have been awarding me a great support above all I would thanks my god who helped me in every ups and down of my work and in my survival. Of all we shall thrust in God for he had bleed and condemned to clean us from our sin. This work will not be even stay like this without the support and motivation of many people around me, so that it is my pleasure to express my appreciation to all of them for standing in my side. Also I thanks to my adviser prof.RATNAM UPPALA ,who encourages me and

advised me to work about this term paper more thanks for his advice and comments he has been giving to me throughout my work and also I will thanks all my teachers and my friends those who helped me in my work.

Gating and riseringby Tesfaye Girma

Abstract................................................................................................................................................... 2 CHAPTER-ONE ......................................................................................................................................... 5 1. INTRODUCTION ............................................................................................................................... 5 1.1. STATEMENT OF THE PROBLEM .................................................................................................. 6 1.2Objective: ................................................................................................................................... 6 1.3. Methodology ............................................................................................................................ 6 CHAPTER-TWO ........................................................................................................................................ 7 2. LITRATURE REVIEW .......................................................................................................................... 7 2.1. GATING AND RISERING.............................................................................................................. 7 CHAPTER ................................................................................................................................................. 9 3. RISERING ......................................................................................................................................... 9 3.1. Criteria for Riser design ........................................................................................................... 10 3.2. Increasing riser efficiency ........................................................................................................ 11 3.3. Rise ring System Design........................................................................................................... 11 3.4. Inscribed circle method for Riser Calculations. ........................................................................ 13 3.5. Modulus Method .................................................................................................................... 13 3.6. Determination of the numbers of Risers. ................................................................................. 13 CHAPTER FOUR ..................................................................................................................................... 14 4. Gating System................................................................................................................................ 14 4.2. The members of the gating system.......................................................................................... 15 Pouring basin. ............................................................................................................................ 15 Sprue. ........................................................................................................................................ 15 4.3. Fluidity of molten metal .......................................................................................................... 16 4.3.1. Factors influencing fluidity ............................................................................................... 16 4.4. Design of Sprues ..................................................................................................................... 19 Runner ....................................................................................................................................... 21 CHAPTER-5 ............................................................................................................................................ 23 CONCLUSIONS ....................................................................................................................................... 23 Reference ...................................................................................................................................... 24

Gating and riseringby Tesfaye Girma

CHAPTER-ONE
1. INTRODUCTION
Casting processes are widely used to produce metal parts in a very economical way, and to obtain complicated shapes with little or no machining. The manufacture of a part involves several steps, the first of which is the design of the part itself, and the specification of the material to be used. This information is passed to the methods engineer, who will choose the casting process, and then design the rigging system necessary to get the molten metal into all regions of the part so as to produce a sound casting. Two major considerations in the casting design are the quality of the final product and the yield of the casting, both of which heavily depend upon the rigging system used.

Gating and riseringby Tesfaye Girma

1.1. STATEMENT OF THE PROBLEM

To gate fast pouring to: Minimize temperature loss during mould lling. To maximize Minimize metallurgical fade. To minimization Minimize oxidation. To clean pouring to: Avoid slag (dross) generation during pouring. To Screen out slag from rst iron poured into mould. For Economic Design: .Maximize casting yield
1.2Objective:

The main objective of this experiment is to enhance the practical knowledge of the students in the field of metal casting technology and to review the basic principles for the design of casting patterns, feeding systems and gating systems, in addition to the investigation of the m Castings without shrinkage defects Economic production maximize casting yield in factors affecting the function of such casting elements.
1.3. Methodology

Design is an integral part of any product or process. Designers go through a number of processes to achieve the final specification from an initial list of requirements known as a design brief.
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Gating and riseringby Tesfaye Girma

Available books journals AutoCAD Internet Different books Drawing

CHAPTER-TWO
2. LITRATURE REVIEW
2.1. GATING AND RISERING

The assembly of channels which facilitates the molten metal to enter into the mold cavity is called the gating system. Alternatively, the gating system refers to all passage ways through which molten metal passes to enter into the mold cavity. The nomenclature of gating system depends upon the function of different channels which they perform. -Richard W Hein Though we have a number of scientific approaches to the design of the gating and rise ring most foundries still prefer to have the traditional way of designing gating & feeding systems by trials and experimentations. Designing a gating system in a purely scientific way demands through knowledge in the thermal and fluid dynamics field. Well this assignment utilizes a classic fluid dynamical approach to design the gating with limited amount of empirical results concluded by the leading researchers of 1960s. An empirical way of rise ring is also formulated with some little success without following the results concluded by prior researchers. As it is a completely theoretical try, the concluded results may not match with the real time situations. And this is where we take the aid of simulation programs.

Gating and riseringby Tesfaye Girma

Riser always blind (closed top). Riser contact generally as short as possible. Designed dimensions always measured at the Notch. Gate thin and wide for fast freezing. Vents to assist fast mould lling

Gating and riseringby Tesfaye Girma

CHAPTER
3. RISERING
Carbon steel experiences shrinkage of about 3% during solidification. Additional volume reduction occurs during the cooling of the liquid metal after pouring. These contractions will create internal unsoundness (i.e., porosity) unless a riser, or liquid metal reservoir, provides liquid feed metal until the end of the solidification process. The riser also serves as a heat reservoir, creating a temperature gradient that induces directional solidification. Without

directional solidification, liquid metal in the casting may be cut off from the riser, resulting in the development of internal porosity. Two criteria determine whether or not a riser is adequate: 1) the solidification time of the riser relative to that of the casting, and 2) the feeding distance of the riser. To be effective, a riser should continue to feed liquid metal to the casting until the casting has completely solidified. Thus, the riser must have a longer solidification time than the casting. Since the critical factor affecting solidification time is heat loss, minimizing heat loss from the riser is an important consideration. For a rise of fixed volume, a minimum amount of heat loss will occur when the riser geometry has the smallest possible surface area. A sphere represents the maximum volume-to-surface-area ratio (V/A, the solidification modulus), and therefore freezes at the slowest rate according to Chorinovs rule. However, spherical risers present molding problems. A cylinder with a height, H, equal to its diameter, DR, is the typically recommended riser geometry, since it is a simple, easily moldable shape having a high volumeto-surface-area ratio. Various insulating or exothermic riser sleeves are available to reduce the heat loss from a riser. Regardless of its shape, the riser must be large enough to provide
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Gating and riseringby Tesfaye Girma

sufficient feed metal without the shrinkage pipe in the riser extending into the casting. As shown in Figure 1, there are two common riser configurations: the top riser, which is typically more efficient, and the side riser. The hemispherical bottom on the side riser prevents premature freezing of the riser/casting junction [1]. It is also recommended to gate the casting through the side riser for maximum effectiveness [1]. The feeding distance (FD) is the maximum distance over which a riser can supply feed. The feeding distance depends in part on the temperature gradient, which is the change in the temperature per unit length during solidification. Figure 5b illustrates how a steep temperature gradient facilitates the feeding of a casting [4]. The shape of the solid skin surrounding the liquid metal varies with the steepness of the temperature gradient during freezing. Steep gradients provide open, more accessible feeding passages. There exists a critical tapering angle for the liquid pool feeding the solidification shrinkage. For liquid pool angles smaller than this critical angle, centerline shrinkage will form in the isolated pools of liquid that are cut off from the feeding path.

Fig.3.1. feature of riser Rise ring is a process designed to prevent shrinkage voids that occur during solidification contractions Aluminum 6.6% Steel 2.5 to 4%
3.1. Criteria for Riser design

Riser must remain molten until casting is completely solidified Riser should have enough liquid metal to feed casting
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Gating and risering Tesfaye Girma riseringby

Riser should be kept at proper distance from the castin casting

fig.3.2.form of riser
3.2. Increasing riser efficiency

1. Blind riser Good for narrow freezing range Create a partial vacuum in the casting due to shrinkage that can draw liquid metal from riser Smaller riser - better yield

2. Add exothermic compound on riser

3.3. Rise ring System Design

Risers are elements of the gating and feeding system, which are intended for displacing shrinkage cavity and porosity outside of the casting. By the principle of directed solidification. The thinner sections of a casting should preferably be located at the bottom and the thicker ones, at the top. The latter communicate with risers above them. If this is impossible, side risers are

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Gating and riseringby Tesfaye Girma

provided for the hot spots. Using internal and external chills can also bring about directed solidification. Drawings of castings are checked for the probability of formation of shrinkage defects by the method of inscribed circle (Figure 1 a), which should freely roll out, as it were, from lower sections of a casting into the upper ones and further into the riser. For the casting shown in Figure 1 a, this condition is not satisfied (R1> R2), and therefore, shrinkage cavity 1 is likely to appear in the hot spot. After marking the machining allowances, draft 2 and fillet 3 in the drawing (Figure 1 b), the inscribed circles will roll out freely (R1< R2) from the bottom of the casting up wards into the riser, which will ensure the directed solidification, and therefore, the absence of shrinkage cavity in the casting.

Fig 3.3.riser system design However, the basic requirement of a riser is that is should: 1. Be the last portion to solidify; 2. Be effective in establishing a pronounced temperature gradient within the casting to promote directional solidification towards the risers; 3. Have sufficient volume to compensate for shrinkage in the casting; 4. Completely cover the casting section that is to be fed; 5. Ensure the maximum yield possible. Apropos maximum yield, one has to know the different shapes of risers in common use - spherical, hemispherical, elliptical, cylindrical, square, rectangular and that, for a particular volume of the riser, the one having the minimum surface area is the most effective.

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Gating and riseringby Tesfaye Girma

3.4. Inscribed circle method for Riser Calculations.

Heuvers was developed this method. The riser diameter is obtained by multiplying the diameter of the largest circle (hot spot) that can be inscribed in the section to be fed by an arbitrary factor which normally ranges from 1.5 to 3, i.e. riser diameter D = 1.5 TO 3 times diameter of the hot spot. Though this method is empirical, it is still very much in use because of its simplicity.
3.5. Modulus Method

The Modulus of a casting M is given by:

=Vc =

Volumeofcasting .3.1 surfaceareaofcasting

In view of the fact that the shrinkage cavity of a riser can amount to a maximum of 14% of its original volume, the modulus of the riser must be at least 1.2 times the modulus of the casting. To ensure that the riser solidifies later than the casting, (theoretically the solidification of the riser will be about 1.44 times that of the casting) after obtaining the modulus, the size of the riser can be calculated by assuming a suitable height to diameter ratio.

= 1.2 M c .3.2

3.6. Determination of the numbers of Risers.

Number of required Risers can be calculated using the following formula

L(mm) ............................................................................3.3 d F (mm) + FD.T (mm)

Where: nF : Risers numbers required. L : Casting length or mean circumference. F d: Is the riser diameter. T : IS the thinnest casting section through which to feed. FD: Feeding distance factor, which is (4-5 for steel), (5 for malleable iron), (10 for AL),(5-6 Al alloys), etc.

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Gating and riseringby Tesfaye Girma

CHAPTER FOUR
4. Gating System
The assembly of channels which facilitates the molten metal to enter into the mold cavity is called the gating system. Alternatively, the gating system refers to all passage ways through which molten metal passes to enter into the mold cavity. The nomenclature of gating system depends upon the function of different channels which they perform.

Down gates or sprue Cross gates or runners In gates or gates

The metal flows down from the pouring basin or pouring cup into the down gate or sprue and passes through the cross gate or channels and in gates or gates before entering into the mold cavity. The metal flows down from the pouring basin or pouring cup into the down gate or sprue and passes through the cross gate or channels and in gates or gates before entering into the mold cavity. Function Trap contaminants Regulate flow of molten metal Control turbulence To establish directional solidification
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Gating and riseringby Tesfaye Girma

The ideal optimum gating system should: 1. Fill the mold quickly. 2. Fill a mold with a minimum of turbulence. 3. Establish thermal gradients, which promote soundness. 4. Avoid re-oxidation of metal in the gating system. 5. Remove slag and dross from the metal as it flows through the gating system. 6. Not distort the casting during solidification. 7. Maximize casting yield. 8. Be economical to remove. 9. Be compatible with the pouring system used
4.2. The members of the gating system.

In the following, the individual members of gating systems and of their assembly will be briefly presented:
Pouring basin.

Pouring basins that contain a well deeper than their depth at the 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 iron entering the sprue. Once the proper location of the ladles lip has been established, fast pour and sprue filling begins with minimum slag entry.
Sprue.

Circular cross sections are being used most commonly. Tapering the sprue downwards is always a good practice. Straight or nearly straight sprues 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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Gating and risering Tesfaye Girma riseringby

Fig.4.1.Sprue Gating system design strongly depends on knowledge of fluid flow Sprue-Runner, Pouring basin, risers Runner,

4.3. Fluidity of molten metal

Fig.4.2.molten metal Fluidity = capability of the molten metal to fill the mold cavities

4.3.1. Factors influencing fluidity

Viscosity: Increasing viscosity and sensitivity to temperature reduces fluidity Surface tension: High surface tension reduces fluidity Inclusions: Insoluble particles reduce fluidity

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Gating and riseringby Tesfaye Girma

Fig.4.7.Step of flow of fluid

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Gating and riseringby Tesfaye Girma

Measuring fluidity A test for measuring fluidity using a spiral mold The fluidity index of the material is the length of the solidified metal in the spiral passage The greater the length of the solidified metal greater is the fluidity Two Principles of fluid flow Bernoullis theorem Law of mass continuity Will help in design of gating system Bernoullis Theorem h + (P/rg) + (v2/2g) = constant fig.4.3.sprue and runner

h: elevation from reference plane P: pressure at the elevation r: density of fluid v: velocity of the fluid g: gravitational constant F : frinction Laws of Continuity fig4.3.flow h1 + (P1/rg) + (v12/2g) = h2 + (P2/rg) + (v22/2g) + f

For incompressible liquids the rate of flow is constant Q = A1V1 = A2V2 Q: rate of flow m3/s A: cross sectional area

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Gating and riseringby Tesfaye Girma

Fig.4.7. Fluid flow V: velocity if fluid flow

Factors Affecting Permeability Gas loss

4.4. Design of Sprues

A1 h2 = A2 As h1 liquid flows down the croaper is provided in the sprue the

Liquid loses contact if sprue is straight-causes Aspiration P1 = P3, Level 1 is constant V1 = 0, assume no frictional loss ght = (v3)2 /2

Time to fill mold Tf = V/ AgV3 Ag : cross sectional area V: volume of mold cavity Flow Characteristics

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Gating and riseringby Tesfaye Girma

Important characteristics in fluid flow is Turbulence as opposed to Laminar Flow Reynolds number

Re = vDr/ V: velocity D: diameter r: density : viscosity Re is usually between 2000 and 20000 For Re above 20000 dross formations occur caused by air and gases Scum on top can get mixed with alloys

4.5. Elimination techniques

Avoid sudden changes in fluid flow Avoid sudden changes in cross section dross can be reduced by filters ( ceramic, mica) Also with proper pouring basin and gating system

4.5. Heat Transfer: Chvorinovs Rule

Solidification time is proportional to volume of casting and its surface area

volume time = C surfaceare a
2

C: constant reflects mold metal properties

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Gating and riseringby Tesfaye Girma

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 4 inch 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.

Fig.4.4.runner Sprue runner junction. The first rule in shaping the sprue-runner junction is that it must not locally decrease the calculated sprue bottom cross-section area. If then, the sprue cross section is largely in any dimension than the horizontal section of the runner, the sprue bottom should extend to the bottom of the runner, see the previous figure. Gates. Gates are the most delicate members of the system, Gates should be thin and correspondingly wide, and should be easy to remove. The optimum gate cross section is rectangular with a little draft as condition permit. Runner-gate Junction.

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Gating and riseringby Tesfaye Girma

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 angles. Gate-Casting junction The gates need to join the thinnest sections of the casting as much as layout limitations permit. The aim is to equalize cooling rate between the different segments of the casting. If delicate cores or soft mold wall would be damaged by the impact of entering stream of iron, gates may be flared out or their cross section increased nearing the casting. Such precaution is seldom used because it increases cleaning room cost, and the reffduction in linear velocity is not significant.
4.6.Classifications of Gating Systems.

According to the hydrodynamics of flow of metal Gating system are divided into open and closed. Closed or pressurized gating systems are characterized by gradually decreeing crosssectional areas of the sprue, slag traps and runners:

sprue > S A runner > S A Gate ..4.5

Better separation of slag, the metal enters the mold cavity with a high linear velocity, which can lead to splashing and oxidation of the molten metal, capture of air, and washout of the mould walls. Closed gating systems are especially popular in the manufacturing of iron castings. Open or non-pressurized gating system is characterized by gradually increasing crosssectional areas of the sprue, slag traps and runners:

sprue < S A runner < S A Gate .4.6

Open gating systems are used in casting of steels, aluminum, and magnesium and other easily oxidable alloys and are coming into use in iron casting.

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Gating and riseringby Tesfaye Girma

CHAPTER-5 CONCLUSIONS
A new set of feeding distance and riser sizing rules has been developed for high alloy steel grades CF-8M, CA-15, HH, HK and HP. By comparing casting trial results with corresponding casting simulation a result, a correlation was developed between the Niyama criterion (a local thermal parameter) and casting soundness. Using this information, extensive casting simulation was used to develop feeding distance rules for a wide range of casting conditions. It was found that the feeding distance rules developed in an earlier analogous study for carbon and low-alloy steels could also be used for the high alloy steels considered, provided that the feeding distance was modified by the appropriate high alloy steel grade multiplier. Other multipliers for these feeding distance rules account for superheat, sand mold material, and the use of chills. The new high alloy feeding distance rules, which are valid for section thicknesses ranging from 2.54 to30.5 cm (1 to 12 in.), are shown to be less conservative than existing feeding distance rules, and are more tailored to the actual casting conditions. In another part of this study, high alloy riser sizing rules were investigated. It was determined that if open top risers are used, the C&LA riser sizing rule (which is less conservative than previously published high alloy riser sizing rules) is applicable for high alloy steels as well. This study also determined that riser size is independent of alloy grade for blind top risers.

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Gating and riseringby Tesfaye Girma

Reference

1. Kalpakjian, S., Manufacturing Processes for Engineering Materials, 3rd ed., Menlo Park, CA, Addison Wesley, 1997 2. Kathie, S. , Chung C.W, Ramani K. & Tomovic M. Methodology for Metal-Casting Process Selection Society of Automotive Engineers, Inc., 2002 3. Mikell P. Groover. Fundamentals of modern manufacturing materials,process, and systems. Prentice Hall.Inc;1996 Schey, J. A. Introduction to manufacturing process.3 rd ed. NY: McGraw Hill ; 2000. 4. Peter Beeley, Foundry Technology First published 1972 Reprinted 1979, 1980, 1982 Second edition 2001 5. Ravi B. Metal casting computer-aided design and analysis. New Delhi: Prentice Hall of India; 2005. 6. Steve Hurst, metal casting Appropriate technology in the small foundry, Intermediate Technology Publications 1996 7. John Campbell the new metallurgy of cast metals, Second edition 2003,First published 1991,Paperback edition 1993

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