Gagging Casting

Gagging Casting
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Bernoulli’s Equation in gating system
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In sand casting, the metal pouring system is extremely crucial because its layout affects the quality of the casting and reduces metal wastage on the pouring system. In this article, VIC will give you a detailed look at the gating system in the casting process.
In the metal foundry, the gating system in casting is a metal pouring system that conducts molten metal into the mold cavity. Metal flows down from the pouring basin into the sprue and passes through the runner and gates before entering the mold cavity.
Designing a gating system requires careful consideration according to the technology, materials, and castings.
This system determines the flow rate of metal to the mold cavity.
If the flow rate is too fast, there is a risk of corrosion while if the speed is too slow it can cause the metal to be cool before filling the chamber, which directly affects the quality of the casting.
The shape and size of the gating system in casting are properly arranged when making the mold. If the gating system is not designed properly, it can cause severe casting defects .
The gating system in casting is designed to serve the following 4 main goals :
A well-designed gating system in casting should satisfy the following requirements:
If the gating system is designed incorrectly, the following errors can occur :
The gating system in sand casting includes:
The Pouring basin is the funnel-shaped inlet, located on top of the system, where metal is poured from the ladles into the mold .
Pouring basin helps to regulate the flow rate of liquid metal and reduces turbulence at the sprue entrance, and helps to separate sediment and slag before entering the sprue.
Sprue casting is a vertical passageway from pouring basin down runner and gates. Liquid metal going down the vertical sprue loses pressure but increases speed due to the effect of gravity.
The sprue cross section can be circular, square or rectangular ( preferably circular ). Sprue is designed to taper down to avoid air aspiration . Bigger end above for metal pick-up, while smaller end connects to runner.
The foot of the sprue is rotated at a right angle to the runner to prevent free fall of liquid metal, known as the sprue well.
Runner in casting is a horizontal channel connecting the sprue well to the gates. Liquid metal will flow from the sprue to the runner and fill the mold cavity appropriately. Runner has the effect of slowing down the speed of liquid metal when it is free falling in a high speed sprue.
Runner must be filled with molten metal to prevent slag from entering the cavity and ensure steady flow.
Ingate is the end of the path and where the mold cavity begins. It leads the liquid metal that flows from the runner into the mold cavity. Depending on the characteristics of the casting, there are different number of ingates.
There are two types of gates: big gate and small gate. The small gate is used for slowing solid casting, while the large gate is for fasting solid casting.
The gate should not have sharp edges as they can crack during pouring so that the sand can be caught in the molten metal into the mold cavity.
The disadvantages of top gate are high metal flow turbulence, poor casting surface.
The bottom gate has the advantage of less chaos and sand erosion than the top gate.
The downside of the bottom gate is that the metal flow can be clogged due to solidification before the mold is full. The temperature range generated by the bottom gate is difficult to reach the standard causing uneven solidification.
There are two types of gating systems: Pressurized Gating System and Unpressurized Gating System . Choosing the right casting system with the correct area ratio will define the quality of the casting.
The Pressurized gating system is a gating system whose cross-sectional surface area decreases gradually towards the mold cavity (smaller than the narrowest downsprue-runner area). The in-gate area is minimized to put pressure on the system. At the gates, the flow rate of liquid metal is almost equal.
Sprue is always full of metal creating back pressure, which reduces air aspiration.
Here metal that is always running at high speeds becomes more chaotic and it is easy to create eddy currents in gates leading to erosion.
This system gives special priority to injection molding with cast iron materials.
The Un-Pressurized Gating System is a gating system whose total surface area of the doors increases gradually towards the mold cavity (larger than the narrowest downsprue area). Liquid metal flow at gates are different.
Gating ratio is the ratio between the cross-sectional area of the sprue to the total cross-sectional area of the runners to the total cross-sectional area of the ingates.
The formula for the gating ratio is As: Ar: Ag.
With the Pressurized Gating System, the gating ratio is usually 1: 2: 1 or 1: 0.75: 0.5. This system is called a “ Gate control system ” because ingates control the flow of the metal .
With the Unpressurized Gating System, the gating ratio is usually 1: 2: 2 or 1: 3: 3 or 1: 1: 3. This system is called a “ Choke control system ” because the choke controls the flow of the metal .
Table of gating ratio for various of materials:
This is the number that helps to predict flow types with different liquid flows. The nature of the flow in the gating system can be established by calculating the Reynolds number:
L: characteristic linear dimension (m)
v: fluid kinematics viscosity (m2/s)
If the flow is turbulent, the grains of sand in the mold will be shot out of the mold and the gating system entering the mold cavity causes problems such as contamination of the casting, air aspiration in the mold, and erosion of the mold wall.
Liquid metals run through different channels in the mold according to Bernoulli’s theorem that the total head remains constant at any section.
w: specific weight of liquid (N/m2)
The gating system must be designed so that the liquid metal is always full. All cross-sections and changes in direction should avoid sharp corners and take advantage of rounded corners .
To design the pouring system, the designer must adhere to the design requirements as outlined above. Here are the formulas to calculate to design a suitable gating system.
Pouring time is the time when metal fills the mold cavity. The longer the Pouring time, the higher the pouring temperature, and the filling of the mold is not guaranteed. The shorter the pouring time, the more chaotic metal flow in the mold leads to die erosion, and excessive shrinkage.
K₁= 2.67 for sections of 10 to 25mm thick.
W’: mass of the casting with gates and risers (kg)
The ideal design of the sprue is that the large top ends and tapers downwards like a parabola. However, for easier production, it is recommended to use a cone cylinder . The minimum gradation level is 5%.
The sprue output circular cross-section is designed based on the area of the choke area and the gating ratio. This helps to r educe disturbances and heat loss .
h1 and h2: metal static pressure head on top sprue and bottom sprue.
A1 and A2: the respective cross-sectional area.
Design of the sprue well : A reasonable sprue well design is to make a cylinder twice the diameter of the sprue exit and twice the depth of the runner. A fillet placed between the well and the runner will help the metal to steer perpendicular smoothly .
The choke is a control area placed in the sprue well to control the flow of liquid metal flowing into the mold cavity so that the mold is filled in calculated pouring time.
The choke area plays an important role in gating systems because the area allows metal to pass through at a consistent and constant flow. The choke has the smallest ratio in the gating system compared to the other parts and cross-sectional area is smallest in the control area.
d: mass density of molten metal (kg/mm3)
C: efficiency of the used gating system (= 0.8)
W: casting weight including feeders and gating channels (kg)
H: sprue height (mm), calculate H by:
The total cross-sectional area of the runner must be greater than the sprue exit to reduce the speed of the metal flow from the sprue to the ingates.
Priority ratio of the sprue exit to runner cross section is 1: 2. Greater proportions may result in flow separation and air aspiration.
If there are multiple ingates, the cross-sectional area of the runner after each passing through the ingate must gradually decrease by an area equal to that of the ingate to ensure a steady flow.
Ingate must be made larger than the sprue exit to speed the metal below the limit.
The Riser is a molten metal cavity in a mold, ready to supply metal to the mold cavity to compensate for shrinkage as the metal cools. It is placed in the final solidification position of the casting, and it is in the liquid state for the longest time. The Riser is also where the gases generated inside the mold are released during the casting process.
The design of the gating system is tested through the following techniques:
VIC is one of the leading casting aluminum and cast iron foundry manufacturers . We are focusing on manufacturing kettlebells with high high quality. If you have any questions or need metal casting foundry cooperation, do not hesitate to contact us by email: business@vietnamcastiron.com
Many thanks Mr. Dinh Tien Vu for this rich technical article
If your have more technical article for publication it will be appreciated
Sir , We at in INDIA (KOLHAPUR , MAHARASTAR) having one WA / Telegram Group for foundrymen and are also conducting various seminars , webinars and also having our own youtube channel for the knowledge sharing to foundry industry all over world. I would like to invite you for the few small video on the gatting design with you on cisco webex platform. we can do these videos recording as per pour convenience and then load it on you tube. Pl send me if you are interested to do it. with us.
Our YouTube channel “Dynamic Foundry Group”
thanks for this document.
Nevertherless there is a mitake in the Reynolds condition.
The flow is turbulent for Re>2000 not for Re <2000
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