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Gating system nothing but the basic design, which is needed to construct a smooth and
proper filling of the mold cavity of the casting without any discontinuity, voids or solid
inclusions. A proper method of gating system is that it leads the pure molten metal to flow
through a ladle to the casting cavity, which ensures proper and smooth filling of the cavity.
This depends on the layout of the gating channels too, such as the direction and the
position of the runner, sprue and ingates.
Objective of the Gating System :
The four main points, which enables a proper gating system, are:
Choke Area
After calculation of pouring time, it is required to establish the main control area
which meters the metal flow into the mould cavity so that the mould is completely
filled within the calculated pouring time. The controlling area is the choke area.
The choke area happens to be at the bottom of the sprue and hence the first
element to be designed in the gating system is the sprue size and its proportions.
The main advantage in having sprue bottom as the choke area is that proper flow
characteristics are established early in the mould.
The choke area can be calculated using Bernoullis equation as
Riser
It is the task of casting designer to reduce all hot spots so that no shrinkage
cavities occurred. Since
solidification of the casting occurs by loosing heat from the surfaces and the
amount of the heat is
given by the volume of the casting, the cooling characteristics of a casting can be
represented by the
surface area to the volume ratio. Since the riser is almost similar to the casting in
its solidification behaviour, the riser characteristics can also be specified by the
ratio of its surface area to volume. If
this ratio of casting is higher, then it is expected to cool faster.
In order to feed the casting, the riser should solidify last and hence its freezing
ratio should be greater than unity.
CAINEs Method
X = { a / Y-b} + c
Where Y = riser volume / casting volume
a, b, c are constants whose values for different materials are given here
Types of risers:-
Various types of risers in use are
I. Side riser(live or hot riser):It is filled last and contains the hottest metal. It
receives the molten metal directly from the runner before it enters the mould
cavity and effective than top riser.
II. Top riser(dead or cold riser); It is located on the top of the casting and has
advantages of additional pressure head and small feeding distance over the
side riser which is placed adjacent to the casting
III. Open riser: These risers are open to the atmosphere at the top surface of the
mould.
Advantages:
Can be easily moulded
Since it is open to atmosphere ,it will not draw metal from the casting as a
result of partial vacuum in the riser
Such risers serve as collectors of non-mettalic inclusions floating upto the
surface.
Limitations:
The height should be adjust with height of the cope, this result partial
vaccum in the risrer
These are the holes through which foreign matter may get into the
mould cavity.
iii. Blind riser :the riser which is not open to atmosphere called as blind riser.
Advantages:
Can be removed more easily
ROLE OF RISER IN SAND CASTING
Metals and their alloys shrink as they cool or solidify and hence may create a
partial vacuum within the casting which leads to casting defect known as
shrinkage or void.
1. The primary function of riser as attached with the mould is to feed molten
metal to accommodate shrinkage occurring during solidification of the
casting.
2. As shrinkage is very common casting defect in casting and hence it should
be avoided by allowing molten metal to rise in riser after filling the mould
cavity completely and supplying the molten metal to further feed the void
occurred during solidification of the casting because of shrinkage.
3. Riser also permits the escape of evolved air and mold gases as the mold
cavity is being filled with the molten metal. It also indicates to the foundry
man whether mold cavity has been filled completely or not. The suitable
design of riser also helps to promote the directional solidification and hence
helps in production of desired sound casting.