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Lectute 7

The document discusses the design of gating systems for casting processes. It describes the key elements of a gating system including the pouring basin, sprue, runner, and gates. It also covers factors that must be controlled like temperature and flow rate. The document provides details on different types of gating systems and their advantages and disadvantages.

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14 views

Lectute 7

The document discusses the design of gating systems for casting processes. It describes the key elements of a gating system including the pouring basin, sprue, runner, and gates. It also covers factors that must be controlled like temperature and flow rate. The document provides details on different types of gating systems and their advantages and disadvantages.

Uploaded by

e22mecu0009
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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LECTURE 7

Design of a Gating System


GATING SYSTEM

The term gating system refers to all passageways


through which the molten metal passes to enter the
mould cavity.
The gating system is composed of ;
✓ Pouring basin
✓ Sprue
✓ Runner
✓ Gates
✓ Risers
Essential Requirements of a Gating System
✓ A gating system should avoid sudden or right angle changes in
direction.
✓ A gating system should fill the mould cavity before freezing.
✓ The metal should flow smoothly into the mould without any turbulence.
✓ Unwanted materials such as slag and other impurities should
not be allowed to enter the mould cavity.
✓ The metal entry into the mould cavity should be properly
controlled in such a way that aspiration of the atmospheric air is
prevented.
✓ A proper thermal gradient should be maintained so that the
casting is cooled without any shrinkage cavities or distortions.
✓ It should be economical and easy to implement and remove
after casting solidification.
Factors to be Controlled

✓ Type of pouring equipment, such as ladles, pouring


basin etc.
✓ Temperature/ Fluidity of molten metal.
✓ Rate of liquid metal pouring.
✓ Type and size of sprue.
✓ Type and size of runner.
✓ Size, number and location of gates connecting runner
and casting.
✓ Position of mould during pouring and solidification.
Elements of Gating System

• Pouring Cup
• Sprue
• Sprue well
• Cross-gate or Runner
• Ingate or Gates
Pouring Basin
• The molten metal is poured into a pouring basin
which acts as a reservoir from which it moves
smoothly into the sprue.
• The molten metal in the pouring basin should
be full during the pouring operation to avoid the
atmospheric air and slag from entering into
mold cavity.
• The molten metal is not directly poured into the
mold cavity because it may cause the mold
erosion due to turbulence.
• The pouring basin also stops the slag from
entering the mold cavity by means of
skimmer or skim core. It holds back the slag
or dirt which floats on the top and allows only
clean metal underneath it into the sprue.
Pouring Basin/Cup
Sprue
• A sprue feeds molten metal to runner which in turn reaches
the casting through gates.
• A sprue is tapered with its bigger end at top to receive the
liquid metal. The smaller end is connected to runner.
Sprue

1 pouring basin
hc sprue
2
ht

1 = free surface of metal


2 = sprue top
3 3 = sprue bottom
• Assuming
– entire mould is at atmospheric pressure (no point
below atmospheric)
– metal in the pouring basin is at zero velocity
(reservoir assumption)
Sprue
Mass flow rate =  A V =constant

Applying continuity equation between point 2 and 3 we get-

A2 V3 2ght ht
= = =
A3 V2 2ghc hc


2
h t  A
=  2

hc  A 3 

11
Runner
• It is located in parting plane and connects the sprue to the in-gates.
• The runners are normally made trapezoidal in cross-section.
• The slag trapping takes place in the runner, when runner flows full,
i.e. if the amount of molten metal coming from sprue base is more
than the amount flowing through the in-gates.
• A partially filled runner causes slag to enter the mold cavity.
Runner Extension
• The runner is extended little further after it encounters the in-gate.
• This extension is provided to trap the slag in the molten metal.
Elements of Gating System

• Pouring Cup
• Sprue
• Sprue well
• Cross-gate or Runner
• Ingate or Gates
Defects occurring due to improper design of gating system

• Oxidation of metal
• Cold shuts
• Mould erosion
• Shrinkages
• Porosity
• Misruns
• Penetration of liquid metal into mould walls.
Types of Gates

• Depending upon the orientation of the parting plane.


– Horizontal Gating System
– Vertical Gating System
Types of Gating Systems
• Depending upon the position of ingate(s), horizontal
gating system.
– Top Gating System
– Bottom Gating System
– Parting-line Gating System
Top Gate

Top Gate:
• A top gate is made in the cope portion of the mould.
• In a top gate the molten metal enters the mould cavity
from the top.
• Top gate involves high turbulence and sand erosion.
• Top gate produces poor casting surfaces.
• Mould filling time is less as compared to other gating
systems
BOTTOM GATE
• A bottom gate is made in the drag portion.
• In a bottom gate the liquid metal fills rapidly the
bottom portion of the mould cavity and rises steadily
and gently up the mould walls.
• As comparison to top gate, bottom gate involves little
turbulence and sand erosion.
• It produces good casting surfaces.
• If freezing takes place at the bottom, it could choke
off the metal flow before the mould is full.
Parting Line Side Gate

• Middle or side or parting line gating systems


combine the characteristics of top and bottom gating
systems.
• Gate is provided along the parting line such that
some portion of the mould cavity will be below the
parting line and some portion will be above it.
• The cavity below the parting line will be filled by
assuming top gating and the cavity above the parting
line will be filled by assuming bottom gating.
Analysis of Pouring and Filling up of the mould

VERTICAL/ TOP GATING SYSTEM


Mold filling time for a top gate system is given by;
BOTTOM GATING SYSTEM
Mold filling time for a bottom gate system is given by;

When ht = hm

Mold filling time for a bottom gating system = twice


that of top gating system
PARTING LINE GATING SYSTEM

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