Traditional Manufacturing Processe

Casting
Forming

Sheet metal processing

Powder- and Ceramics Processing

Plastics processing

Cutting

Joining

Surface treatment
 Sand Casting
Pattern
Pattern Basics Completed
Pattern
materialsTypes of
patterns Pattern
allowances
Mould design &
Preparation Molding Materials
Molding sand
( types, quality , testing)
Mould preparation
Melting Cast metal pouring system
furnace
Casting
1. Function of mould arising to different sands ( e.g moulding
sand , facing sand etc.)

2. What will be properties required to meet the functions.

3. Types of sands used ( backing sand, facing sand, parting

sand, system sand)
 Functions/ Properties of mould

- during sand filling and ramming , sand should flow to all

areas with proper compactness ( flowability)
- during mould preparation, should bind properly ( green
strength)
- during metal pouring , should dry and not be broken ( dry
strength)
- during metal pouring, should withstand high temperature ( hot
strength/ refractoriness)
- gases should come out easily ( permeability)
- should break easily during final casting taken out
(collapsability)
 Varieties of sand

Based on processing properties

1. Moulding sand
2. Backing (system) sand
3. Facing sand
4. Mould wash
5. Parting sand
6. Core sand
 Types of Sand
Facing Sand
• used next to pattern for easy removal and increasing
smoothnes.
• coal dust 2-8% is mixed with the system sand.
• coal dust burns resulting into gas pressure thus
protecting molten metal entering into sand.

Mould wash
• similar sand like facing sand but used after pattern is
taken out ( through spraying, painting etc.).
• water/ alcohol is used to mix the sand. Alcohol is
preferred because of faster evaporation.
 Types of Sand
Backing Sand
• reconditioned sand ( after the sand mould is broken).
• used as cost effective requirement.
• facing / mould wash sand is used in conjunction.

Parting sand
• used at the parting line of the pattern.
• avoids adherence of the pattern with the moulding
sand.
• washed silica sand helps for it’s non-stickiness
properties.
 Mould design &
Preparation
Molding Materials

Sand Binder Water Additives

( silica) ( e.g clay) (cereal etc)

a. Natural sand
b. Synthetic
c. Special
Important to understand for design of mould, runner
system, casting defects
 Moulding Materials
Major part of Moulding material in sand casting
are
1. 70-85% silica sand (SiO2)
2. 10-12% bonding material e.g., clay , cereal
etc.
3. 3-6% water

Requirements of molding sand are:

(a) Refractoriness
(b) Cohesiveness
(c) Permeability
(d) Collapsibility
(e) Other properties
1. Refractoriness:
It is the ability of the molding material to
with stand high temperatures
(experienced during pouring) with out
1. Fusion,
2. Cracking, buckling or scabbing,
3. Experiencing any major physical
change.
The properties widely varies with type of
material as given in next slide.
 Properties of some refractory materials
Material MP , 0C Coeff of L Exp,
x106/0C

Silica (SiO2) 1710 16.2

Alumina (Al2O3) 2020 8
Magnesia (MgO) 2800 13.5
Thoria (ThO2) 3050 9.5
Zirconia (ZrO2) 2700 6.5
Zircon (ZrO2.SiO2) 2650 4.5
Silicon Carbide(SiC) ~2700 3.5
Graphite ~4200 -
 2.
Permeability:
• Ability to escape gases absorbed by the metal during
melting, air absorbed from the atmosphere and the
steam generated by the molding and core sand.
• If not escaped, they result in gas holes/ pores in product.
• To overcome this problem the molding material must be
porous.

Factors for permeability

Quantity/Quality of clay /quartz in the sand mixture
Moisture content
Degree of compactness
 3. Green
Strength:
• The molding sand that contains
moisture is termed as green sand.
• The green sand particles must have the
ability to cling to each other to impart
sufficient strength to the mold.
• The green sand must have enough
strength so that the constructed mold
retains its shape.
• Green strength helps in making and
handling the moulds.
 4. Dry
Strength:
• A mould may either intentionally be dried, or
a green sand mould may lose its moisture
and get dried while waiting for getting poured
or when it comes in contact with molten
metal being poured.
• The sand thus dried must have dry strength
to
1. Withstand erosive forces due to molten
metal,
2. Withstand pressure of molten metal,
3. Retain its exact shape
4. Withstand the metallostatic pressure of
the liquid material.
5. Hot Strength:
6. Collapsibility:
• Collapsibility determines the readiness
with which the molding sand,
1. Automatically gets collapsed after
the casting solidifies, and
2. Breaks down in knock out and
cleaning operations.
• If the mould or core does not collapse, it
may restrict free contraction of solidifying
metal and cause the same to tear or
crack.
7. Flowability:
• It is the ability of the molding sand to
get compacted to a uniform density.
• Flowability assists molding sand to flow
and pack all-around the pattern and
take up the required shape.
• Flowability increases as clay and water
contents increase.
8. Adhesiveness:

It is the property of molding sand owing

to which, it
1. Sticks with the walls of molding
boxes,
2. Sticks with gaggers, and
3. Thus makes it possible to mold
cope and drag.
 9.
Fineness:

• Finer sand mould resist metal

penetration and produce smooth
casting surfaces.
• Fineness and permeability are in
conflict with each other and hence they
must be balanced for optimum results.
 Molding sand
1. 80-90% silica (SiO2)
Natural sand 2. 5-10% Alumina (Clay )- binder
( Silica sand) 3. Lime/ magnesia
4. 2-8% water addedb(to activate clay)

Advantages Disadvantages
1. Less costly 1. Get fused with metal
2. Easily available 2. High coefficient of expansion
3. Wide range of grain sizes
and shapes

These sands are got from river and can withstand upto 1550 deg C

d for light castings in both ferrous and non-ferrous me

 Molding sand
1. Base sand is Natural sand
Synthetic sand 2. Bentonite is added
3. Oxides of iron, calcium and
magnesium are added
4. 2-8% water added
Advantages Disadvantages
1. More uniform grain sizes. 1. Costlier
2. Easy mouldability. 2. Need special preparation
3. Higher refractoriness.
4. Easy control of properties

sed in case of :
. Mechanised production ( high volume)
. Machine molding
. High pressure molding
 Molding sand
Special sand ( are available in specific
area or made from minerals)
1. Zircon sand - better properties
2. Chromite sand - but costlier
3. Olivine sand - need special preparation

1. Zircon sand 1. Fusion point 2400 deg C

- Zircon Oxide ( ZrO2) - 66% 2. Low thermal expansion
- Silica (SiO2) - 31% 3. Higher conductivity means higher
- Alumina (Al2O3) - 2% cooling rate
- Iron Oxide (Fe2O3) - 1% 4. Requires 3% binder against 10% for
natural sand
5. Available in Quilon beach of Kerala

d for precision investment castings (steel+better fin

 Special Molding sand

. Chromite sand 1. Fusion point 1800 deg C

- chromite ( Cr2O3) - 44%
2. Low thermal expansion
- Iron Oxide (Fe2O3) - 28%
3. Requires 3% binder against 10% for
- Silica (SiO2) - 3%
- Al2O3+MgO - 25%
natural sand
-

Used for heavy steel castings (austenite

+manganese steel) requiring high surface finish.
 Special Molding sand

3. Olivine sand 1. Fusion point (1550-1800 deg C)

- fosterite ( Mg2SiO4)
2. Versatile
- fayalite ( Fe2SiO4)

Used for range of steels

Binder
Provides strength/ cohesiveness
Binders are of many types such as:
•Clay binders,
•Organic binders (Oil)
•Inorganic binders (resin)

Clay binders are most commonly used. The most popular

clay types are:

Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O) and Bentonite

(Al2O3 4 SiO2 nH2O)

Of the two the Bentonite can absorb more water which

increases its bonding power. But has lower melting temp
( 1300 deg C compared to 1800 deg C for Kaolnite)
[Link] has higher moisture content
( Kaolinte)
[Link] has higher melting point
( Kaolnite)
[Link] has higher permeability
( Bentonite)
[Link] has higher strength ( Bentonite)
[Link] u want higher refractoriness of binder
compared to sand ( No, lower
refractoriness helps the collapsability
property of sand )
[Link] other constituents should be added
to clay ( lime, alkalies, oxides to reduce
refractoriness)
 Additives
1. Cereal +Molasses+Ethylene glycol ( upto 2% ) increases wet
strength. Resistance to drying out

2. Cereal+Saw dust ( upto 1.5%)- collapsibility enhancement

and resistance to expansion. Permeability is enhanced.

3. Pitch (by product of coke- upto 3%) increases hot strength

4. Iron oxide+silica flour (upto 3%)- hot strength development.

Substitute to mould wash. Chilling effect on the mould. But
the green strength/ permeability/ collapsibility are decreased

5. Coal dust+silica flour-improves surface finish and resistance

to metal penetration.
 Testing Sand Properties
25 sand testings
Procedure for sample preparation
 Important sand testing
1. Moisture content
2. Permeability
3. Green compression strength
4. Green shear strength
5. Dry strength
6. Mould hardness
7. Grain size & distribution
8. Active clay content
9. Mouldability
10. Friability
11. Loss on ignition
12. Volatiles content
13. Dust (dead clay) content
1.0- Moisture Content
-test sample of 50 gm is prepared
- dried at 105-1100C for 2 hours
- take weight again
- difference in weight= moisture content
- alternate method is passing hot air in a set-up
- acetylene pressure (C2H2) can also be a measurement
criteria. Calcium carbide absorbs moisture (H2O).
2.0- Permeability
-permeability is the ability ( time taken) to pass air by sand
under rammed condition.
- 2000 c.c. of air at pressure 980 Pa
- specimen size 50.8 mm dia, 50.8 mm length
- both green and dry permeability are checked
 5.08 cm
Permeability number

P= V. 5.08 cm
[Link]. T

V - volume of air ( 2000 c.c.)

H - height of specimen (5.08 cm)
p - air pressure ( g/cm2)
A - cross sectional area of specimen ( 20.268
cm2)
T - time taken for complete air pass in minutes.

P= 501.28
p. T
3.0- Green compression strength
- sand specimen prepared ( as per standard) is immediately
tested under compression loading .
- value (30-160 kPa)
4.0- Green shear strength
-test specimen preparation same as earlier.
- testing is for shearing test in UTM
- value is lower ( 10-50 kPa)

5.0- Mould hardness

- hardness testing method similar to Brinell hardness test
- spring loaded steel ball with mass of 0.9 kg is pressed
onto the specimen and depth is measured
- Brinell hardness number (0-100)
6.0- Dry strength
- test specimen preparation is dried @ 105-1100 C for 2 hours.
- tested in the following type of strength testing machine.
- value is higher ( 140-1800 kPa)

Tensile strength
preparation core box
7. Sand Grain Size (GFN)

GFN is the average size and corresponds to an sieve number

through which all the sand grains would pass through, if they
were all of same sizes.

It normally varies from 40-220 in practice ( 6 –pan)

Lower the value, higher is grain size.

GFN :
41 - steel castings 50 kg+
67 - small steel casting
105 - light cast iron/ cu- casting
150 – aluminium alloy casting
GFN testing set-up
Sizes and example
Sizes and example
 Moulding sand properties

1. Sand grain shape and size

2. Clay type and amount
3. Moisture content
4. Methods of preparing sand mould
Effect of moisture, grain size and shape on mould
quality
 Mould preparation
1. Sand mixing and preparation
2. Mould and core making
3. Mould assembly and handling
 Mould preparation
Step-1: Mixing moulding sand with binders &
adhesives

Mueller machine is used to mix all sand ingredients properly

 Mould preparation
Step-2: Filling moulding sand in moulding
flask
 Mould preparation
Step-3: compacting sand
1. Jolting
2. Sqeazing
3. Sand slinging
Jolting is dropping the flask filled with sand
from a height repeatedly so that sand is
filled over the pattern

Sand slinging is done through sand into

the flask with great force. This is a fast
process and results into uniform hardness
 Mould preparation
Step-3: placing pattern and squeazing
moulding sand
a) conventional
flat head;
b) profile head;
c) equalizing
squeeze pistons
d) flexible
diaphragm.
 Types of Sand Mold
• Green‑sand molds - mixture of sand, clay, and water
or oil;
– “Green" means mold contains moisture at time of
pouring.
– Most commonly used for faster production
– Moulding flask is recirculated at a quicker rate and
thus helps to reduce inventory and space.
– Least expensive
– Hot tearing problem is eliminated
– Mould damage and permeability are concerns
– Used for low weight castings
 Types of Sand Mold
• Dry‑sand molds
– Normally organic binders are used for getting
better dry strength ( drying temp 150-3500C for 8-
48 hours)
– Higher strength and better life
– Used for medium to large casting
– Distortion during baking to be controlled.
– Hot tearing is a problem
– More expensive
 Types of Sand Mold
• Skin-Dried molds
– Only the mould wall in contact with hot metal is
dried (15-25 mm through torch, spray etc)
– Pouring of metal should be very immediately after
the drying is over
– Used as an in between demand of green sand
mould and dry sand mould.
Cores and Chaplets Coreprint

a. job b. pattern to form c. core

coreprint

-used when castings have holes, recess of various sizes

and shapes
-when using cores, provisions in the mould should be
provided to support them
- core prints ( added projections in the pattern which
form an impression on the mould ) are used to support
them
- core can be mounted horizontally, vertically and hanged
inside the mould
 Design of Core
[Link] – sand
casting
[Link] - die casting
A core has to have
1. Higher green strength ( retain shapes till
dried )
[Link] buoyancy of the molten metal and thus
higher dry strength
[Link] refractoriness (more heat for a longer
duration.)

[Link] collapsible ( otherwise hot tear

problem during solidification)
[Link] heat to the mould
[Link] gases better. Higher permeability
 Design of Core
Weight of core body
Wb=π/4 x d2 x l x ρ core
Horizontal core
Weight of core print
Wp=π/4 x D2 x a x ρ core
D
Total weight= Wb+Wp
a/ l Buoyancy force on core
2 B=π/4 x d2 x l x ρ metal
Net force upward (P)=B-Wb in Newton

ρ core- value is normally 0.0165 N/cm3

metal - value differs for different types (0.073 N/cm3 for Cast iro
 Design of Core
Vertical core Weight of core
Wc=Volume x ρ core

a Weight of volume displaced

Wmetal=Volume x ρ metal
Di H
Net buoyant force= Wmetal-Wc,
a Where,

D Volume=π/4 x (Di2-D2) x H
+
π/4 x (D2) x 2a
 Design of Core

For design of core area, an empirical value of 3.5 N/cm2

( 350N/mm2) is considered.

Thus net buoyant force (P) as calculated in earlier

discussions, should meet the following critera

P≤ 350 A

Where A is core area in mm2

Core type & location
Types :
[Link] sand core
• Done by pattern in the mould itself
• Low compression strength
• Thus requires large draft angle
• Economical
[Link] sand core
• Specially done in core sand box
• Baking required
• Costly and time taking
• High melting cast metal require
Core type & location

Locations :
1. Horizontal simply supported core
2. Horizontal overhanging or side core
3. Vertical double supported core
4. Vertical hanging core
5. Vertical bottom core
 Design of Core

Unbalanced core Balanced core

Vertical core Horizontal core Drop core

 Chaplets

Above has only one coreprint, which can’t

take sufficient load during metal pouring,
solidification
Sand Cores and Chaplets

One side coreprint

Other side Chaplet
 Chaplets
• chaplets are used mostly when core is supported by one core
print.
• are made up of metals which become part of the casted part
• if too small, melts before the solidification, thus causing
stability problem. If too large don’t melt and thus remain with
the casted part and thus problem.
• usage should be avoided or minimise as they cause casting
defects.
 Sand Casting
Pattern
Pattern Basics Completed
Pattern
materialsTypes of
patterns Pattern
allowances
Mould design &
Preparation Molding Materials
Molding sand
Completed
( types, quality , testing)
Mould preparation
Melting Cast metal pouring system
furnace
Casting
Metal Pouring System
 Gating System- Functions
 Minimise turbulent flow to reduce casting defects / mould damage
 Regulate the entry of molten metal into the mold cavity
 Ensure complete filling of mold cavity at minimum time
 Promote a temperature gradient within the casting so that all cross
sections irrespective of sizes and shape can solidify properly.
 Incorporate a system to trap non-metallic inclusions.
 Casting yield should be highest.
 Cast metal pouring system

1. Laddle
2. Pouring cup/ basin
3. Sprue (down-gate) (1)
4. Gate (in-gate)
5. Runner (cross-gate) (6)
6. Riser (6)
(2)
(3)

(5) (4)
 Gating System- Design
One of the most important design criteria of gate design is to
ensure that metal reaches all cross sections in a streamline flow.

This is checked by a fluidity test

A test method for fluidity

using a spiral mold. The
fluidity index is the length
of the solidified metal in
the spiral passage. The
greater the length of the
solidified metal, the
greater is its fluidity.
 Fluid Flow and Solidification Time
p v2
Bernoulli’s theorem h+ + =con
stan
t
ρg 2g

Mass continuity =
QAv
11=A
2v
2

A1 h
Sprue design = 2
A2 h1

Reynolds number

 V olu
me n
Chvorinov’s Rule S
olid
ific
atio
ntim
e =C 
Su
rfa
ceAre
a 
 Hydraulic Principles used in the Gating Syste
Reynold's Number
Nature of flow in the gating system can be established by
calculating Reynold's number
     

                         

    
RN       =         Reynold's number
     
V        =         Mean Velocity of flow
   D        =         diameter of tubular flow
   µ        =         kinematics Viscosity    =  Dynamic
viscosity / Density
   ρ          =        Fluid density
RN< 2000, then streamline flow. Otherwise turbulent flow.
Turbulent flow can result in :

a) absorption of gases b) Inclusion of dross or slug c) erosion of

mold surfaces
Lets say, p=0 at laddle and
mould entry position, then

V=√2gh
If h=0.1 m, g=10 m/s2,then
V=1.4 m/sec h

Using this velocity and

Reynold’s number can be
calculated to check whether
the flow is steady or turbulent
 Design of Gating system
1. Pouring basin

D 2.5 D

Green sand Dry sand

- stream line flow avoids air entrapment

- avoids mould damage
- is in the cope
- inclination ( draft ) is upto 45 Deg
- skim core ( or strainer core) ensures
smooth flow and restriction of flow of slag
 Design of Gating system
2. Sprue : connects pouring basing to cross-gate ( runner)

Tapered sprue
Straight sprue

- avoids air entrapment in liquid metal

- taper on the downside . Why ?
 Sprue tapered downward ?

A Metal being poured at basin at “

B h1 v=0, p=0, h=0

At “B”, h=h1
h2-h1
p=0, v1=√2gh1
C PL
 Sprue tapered downward ?
p v2
h+ + =c
A ρg 2 g
B h1
=
QA
v
1=
1 A
v
22

h2-h1
to maintain constant
head ( otherwise
C PL vortex), then Bernoulli’s
theorem will be

√h1/h2=v1/v2

hence,
A1 h2
=
A2 h1
Sprue Well

 reservoir of metal at bottom

 is designed when flow direction changes sharply
 helps to avoid turbulent flow
 reduce mould damage
 sprue cross section area=1/2 of runner cross
section area
 Design of Gating system
3. Runner (cross-gate) – from sprue well to gate

slug

Runner full Runner partially full

1. Avoids slug entry into mould

2. liquid metal should run full in
runner
 Design of Gating system
4. Gate ( in-gate to mould) can be of various types
depending on the configuration of parting line, part geometry

Top Gate
- to have a strainer core to
reduce velocity of flow
- perpendicular to PL Top gate
- symmetrical geometry part
- good for flat casting (low
height)
- problem of turbulence
- NG for non-ferrous matl
 Design of Gating system

Bottom Gate
- for parts where major portion remains in the drag, tall casting
-Turbulence problem is avoided
- directional solidification problem

Bottom gate
 Design of Gating system

Parting Gate
-easy to dismantle/ fettle

Parting gate

Parting line
 Design of Gating system

Step Gate
- for parts where uneven geometrical shapes and
large parts
Step gate
 Types of Gating System

1. Pressurised Decreasing 2. Un-pressurise

cross sect
area

Increasing
cross sect
area

• Backpressure is • Restriction only at the

maintained. bottom of sprue.
• Backpressure helps to • Air aspiration chances
avoid air aspiration. high.
• Flow of liquid is almost • Turbulence flow
equal from all gates avoided.
• But, can lead to turbulent
 Solidification in a Cube casting

Liquid Liquid
Liquid
Void

How to solve this problem / defect in casting ?

 Solidification Time
Chvorinov’s Rule

 V o
lu
me 
n
S
o
lid
if
ic
a
tio
ntim
e 
=C 
S
ur
f
ac
eAr
e
a 
n =1 for die casting C=constant for a metal
=2 for sand casting

Sphere, cube and a cylinder with the same volume (V=1)

Solidification Time

Fastest
 Risers

 V o
lu
me n
Chvorinov’s Rule S
olid
ific
atio
ntim
e =C 
S
urfa
ce
Are
a 
How to solve problem of solidification ?

Risers can
help to avoid
this void
 Risers

Risers

Also known as metal reservoirs , feeders or

headers
Provide extra metal to compensate for the volumetric
shrinkage
Allow mold gases to escape
Provide extra metal pressure on the solidifying mold to
reproduce mold details more exact
 Riser Design
 Risersfeed liquid metals to the solidifying casting as
a means of compensating for solidification
shrinkage

 Thickest fast solidify last and riser must feed to this

part.

 The riser must not solidify before the casting.

 The riser volume must be large enough to provide a

sufficient amount of liquid metal to compensate for
shrinkage in the cavity.
 Riser Design
 Junctions between casting and feeder should not develop a
hot spot where shrinkage porosity can occur.

 Risers must be placed so that the liquid metal can be

delivered to locations where it is most needed.

 There must be sufficient pressure to drive the liquid metal

into locations in the mold where it is most needed.

 The pressure head from the riser should suppress cavity

formation and encourage complete cavity filling.
 Types of Risers
1. Top riser- additional pressure head and smaller feed distance
2. Side / Blind riser – bigger in size
 Chills
Used where Risers can’t be used to compensate liquid
shrinkage

Because of faster cooling , hard spot is formed near chill

 Gating System Design

Pouring time
- too fast pouring causes turbulence

- too slow causes solidification and thus requirement

of higher pouring temp

-depends on pouring metal ( fluidity K), part thickness

(T) and overall weight ( W)
 Pouring time
For cast iron
t ( seconds)= K[1.41+T/14.59] √W ( for W < 450 kg)

= K[1.41+T/14.59] 3√W ( for W > 450 kg)

Where,

K is fluidity in inches/ 40
T is average section thickness ( V/A) in mm
W is mass of casting in kg

It ranges from 2-3 seconds to few minutes

For other various metals , please refer to reference books.

 Choke Area

Applying Bernoulli’s equation, Choke area

A ( in mm2)=W/ (d t C √2gH)
W is mass of casting in kg
d is density of casting metal in kg/mm3
C is efficiency factor dependent on gating design
H is total metal head in mm
t is pouring time in seconds
 Choke Area

For Top Gate

H=h

H is total metal head

h is sprue height
c is total height of mould cavity
 Choke Area

For Bottom Gate

H=h-c/2
 Choke Area

For Parting Gate

H=h-p2/2c

p is height of mould cavity in cope

Example

Calculate the gating requirement for the cast iron in C30 steel
Solution
Step -1 : calculate the total volume in mm3

Step-2 : calculate the mass in kg ( take density= 7.6 x 10-6

kg/mm3)

Step-3 : calculate total mass to be made through same gating

system ( x2 in this case)

Step-4 : take casting yield around 0.6 and calculate input weight

Step-5 : calculate pouring time ( for given T, W, metal type)

Step-6 : calculate choke area ( take C=0.73, H=150 mm)

Solution
Process of solidification
Schematic illustration of three
cast structures solidified in a
square mold: (a) pure metals; (b)
solid solution alloys; and ©
structure obtained by using
nucleating agents.
Heat transfer- Sand casting

2
V 
ts ≈  
 A
• Cooling for Sand Mold

AIR MOLD SOLID LIQUID

Tw
TEMPERATUR

METAL - MOLD
∆T
INTERFACE
E

MOLD - AIR
∆ T INTERFACE
T0
DISTANCE
Heat transfer- Die casting

1
V 
≈
ts  
A
Thermal Conductivity “k” of Various Materials
for Parts and Molds (W/m °K)

Copper 394
Aluminum 222
Iron 29
Sand 0.61
PMMA 0.20
PVC 0.16
dT
q = −k
dx
Cooling Time; thin slab
Cooling Time; intersection

  
V h  1  1 
= 1 +  
A 2  2  L − 1 
 
  h 
 Fluidity of Metals

Characteristics of molten metals

• Viscosity
• Surface Tension
• Inclusions
• Solidification pattern of the alloy

Casting parameters
•Mold Design
•Degree of Super Heat
•Mold Material
- Thermal Conductivity
- Surface Roughness
•Heat Transfer
• Rate of pouring
 Heat Transfer

• Heat transfer is important in many aspects

of casting

– - Pouring
– - Solidification
– - Cooling rate
• - Rate is a function of
Volume and surface
area
 Hydraulic Principles used in the Gating System

How to avoid turbulence ? Proper design of Gating system

1. Sharp flow changes should be avoided. ( No sharp corners)

2. Gating system should be designed so as run always with full liquid.
3. Tapered sprue help to avoid air aspiration as always liquid would be filled.