15MEC - 213
Manufacturing Technology-I
Subject: 15MEC 213-ManufacturingTechnology-I
Class: 4th Sem [Link]-Mech ‘A’
06/27/2020 1
Solidification time
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Gating System
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Elements of Gating Systems
• 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
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Gating Systems
Requirements needed in gating system to achieve
a free casting defects:
1- The mould should be completely filled in the smallest time
possible without having to rise metal temperature.
2- The metal should flow smoothly into the mould.
3- The unwanted material – slag – should not be allowed to enter the
mould cavity.
4- The metal entry into the mould cavity should be controlled.
5- A proper thermal gradient be maintained.
6- Metal flow should be maintained to avoid erosion.
7- Be ensure that enough molten metal reaches the mould cavity.
8- The gating system should be economical and easy to implement
and remove after casting solidification.
9- The casting yield should be maximized. 11
Gating Systems
Factors controlling the functioning of gating system:
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.
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Pouring Basin
• A pouring basin makes it easier for the ladle or crucible operator
to direct the flow of metal from crucible to sprue.
• Helps maintaining the required rate of liquid metal flow.
• Reduces turbulence at the sprue entrance.
• Helps separating dross, slag etc., from metal before it enters the
sprue.
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Sprue
• A sprue feeds 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.
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Gates
• A gate is a channel which connects runner with the
mould cavity and through which molten metal flows
to fill the mould cavity.
• A small gate is used for a casting which solidifies
slowly and vice versa.
• A gate should not have sharp edges as they may
break during pouring and sand pieces thus may be
carried with the molten metal in the mould cavity.
• Types
• Top gate
• Bottom gate
• Parting line side gate
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Gates
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.
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Gates
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.
• Bottom gate produces good casting surfaces.
• If freezing takes place at the bottom, it could choke
off the metal flow before the mould is full.
• Creates an unfavourable temperature gradient and
makes it difficult to achieve directional solidification.17
Gates
Parting Line Side Gate:
• Middle or side or parting 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.
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Runner
• It is horizontal plane which connects the sprue to
gate.
• The runner should be filled with molten metal to
avoid slag entering to cavity.
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Design of Gating System
• To fill the mould cavity without breaking the flow
of liquid metal and without using very high pouring
temperatures.
• To avoid erosion of mould cavity.
• To minimize turbulence and dross formation.
• To prevent aspiration of air or mould gases in the
liquid metal stream.
• To obtain favourable temperature gradients to
promote directional solidification.
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Improper Gating System Design Defects
• Oxidation of metal
• Cold shuts
• Mould erosion
• Shrinkages
• Porosity
• Misruns
• Penetration of liquid metal into mould walls.
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Design of gating system
The sequential steps are:
a. Estimation of optimum pouring time of
casting,
b. Calculation of sprue choke-area,
c. Selection of gating ratio,
d. Selection of type of gating/location and
finally
e. Calculation of runner, ingate sizes.
f. Slag trap system
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Gating System Design
Pouring Time
The time for complete filling of a mould .
Too long pouring time ===== higher pouring temperature.
Too less pouring time ===== turbulent flow in mould.
Optimum time is required
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Gating System Design
Pouring Time
The pouring time depends on:
- Casting materials,
- Casting complexity,
- Casting size, and
- Section thickness.
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Gating System Design
Pouring Time
1- Gray cast iron: mass less than 450 kg:
T
t K 1.41 W
14.59
fluidity of iron in inches
K
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K: fluidity factor.
T: average section thickness, mm
W: mass of the casting, kg
2- Gray cast iron: mass greater than 450 kg:
T 3
t K 1.236 W
16.65 26
Gating System Design
Pouring Time
3- Steel casting:
t 2.4335 0.3953 log W W
4- Ductile iron:
t K1 W
K1 = 2.08 for thinner sections.
K1 = 2.67 for sections of 10 to 25 mm thick.
K1 = 2.97 for heavier sections.
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Gating System Design
Pouring Time
5- Copper alloy castings:
t K2 3 W
Top gating 1.30
Bottom gating 1.8
Brass 1.9
Tin bronze 2.8
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Gating System Design
Pouring Time
6- Intricately shaped Thin walled castings of mass up to
450 kg:
t K3 3 W
W’: mass of the casting with gates and risers, kg
T, (mm) K3
1.5 up to 2.5 1.62
2.5 up to 3.5 1.68
3.5 up to 8.0 1.85
8.0 up to 15.0 2.20
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Gating System Design
Pouring Time
7- Castings above 450 kg and up to 1000 kg:
t K 4 3 W T
T, (mm) K4
up to 10 1.00
10 up to 20 1.35
20 up to 40 1.50
40 and above 1.70
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Gating System Design
Choke Area
It is the main control area which meters the metal flow
into the mould cavity so that the mould is completely filed
within the calculated pouring time.
W
A
d t C 2 gH
A: choke area, mm W: casting mass, kg
t: pouring time, S H: sprue height, mm
d: mass density of the molten metal, kg/mm3
C: efficiency of the used gating system.
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Gating System Design
Choke Area
Top gate
H=h
Bottom gate
H = h – c/2
Parting gate
H = h – P2/2c
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Gating System Design
Selection of gating ratio
Gating ratio is -
sprue choke area : total runner area : total in gate's area
This is selected depending on the characteristics of molten metal being cast such as fluidity,
slag or dross forming tendency, pouring temperature etc .. , and also on mold material
characteristics such as resistance to erosion, scabbing tendency, green sand,
C02, dry sand, shell-molded etc.
Eg:-For aluminum casting in green sand molds: it is 1 : 2 : 4 and for steel in dry-sand molds: it
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is 1 : 2 : 1.5.
Sprue
• As the liquid metal passes down the sprue it
loses its pressure head but gains velocity.
• To reduce turbulence and promote Laminar
Flow, from the Pouring Basin, the flow begins
a near vertical incline that is acted upon by
gravity and with an accelerative gravity force
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Gating System Design
Sprue
1 pouring basin
hc sprue
2
ht
1 = free surface of metal
2 = spue 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) 35
Gating System Design
Sprue
Mass flow rate = A V = constant
Applying continuity equation between point 2 and 3 we get-
A2 V3 2 ght ht
A3 V2 2 ghc hc
2
ht A2
hc A3
Actual shape of sprue is Parabola
But in order to avoid manufacturing difficulty we use
tapered cylinder shape. 36
A Sample design
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Normally for a casting weighing more
than 35 Kg more than one sprue is to
be provided.
Sprue height is determined by the
mold box height and the diameter of
sprue at top is determined by the draft
taper requirement.
Area at the top of the sprue is normally
about three times that of the bottom. A
round sprue is easier for molding.
Rectangular sprues are preferred for
magnesium alloys.
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• Sprue-well is an enlargement at the bottom of the sprue and
is provided to reduce the turbulence that occurs in changing
the direction of flow from
• vertical to horizontal sprue base can be either cylindrical or
rectangular.
• depth of sprue well= 1.5 to 2 times-runner depth.
• length of sprue well= 4 x (sprue diameter)
• Runners' cross-sectional area is calculated as 2 to 4 times the
sprue choke area. Individual runner area is obtained by
dividing this value by the number of runners connected to
the sprue.
• Runner shapes are normally trapezoidal for a smooth flow.
All dimensions of the runners cross section are calculated
based on the sprue cross sectional area.
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