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Designing For Eliminating Defects in Aluminium Casting
Designing For Eliminating Defects in Aluminium Casting
2
Density of aluminium = 2.7 g/cm
Efficiency factor(C) = 0.90 (from table)
Therefore ,
Choke Area =
= 1.18 cm
2
Choke diameter (dc) = 1.23 cm
( )
( )
c
A
15
Runner and Gate design
calculation:
For Aluminium casting gating ratio= 1:3:3
Runner Area = 3 X
= 3 X = 3.6 cm
2
Assuming trapezoidal cross section and w:h=1,the
runner dimension would be = 31.49 /28.41cm
(approx.).h=1.2,w=1.2 cm.
Calculating the in gate area and dimension;
length and width of gate
hight is 0.67and width is 2.68
4
2
c
d H
16
( )
4
23 . 1
2
H
Top dia of spure= 1.44*1.23
=1.49cm
hight of sprue=4.5cm
bottom dia of sprue is 1.2
17
Calculation of Sprue Area
Law of continuity (Q)= AV =AV
Velocity at inlet( V ) :
Velocity at exit of sprue ( V )
t
gh v 2
2
=
s cm
s cm
/ 65 . 21
65 . 21 23 100 81 . 9 2
=
= =
s cm
s cm
gh v
/ 045 . 99
/ 045 . 99 5 100 81 . 9 2
2
1
=
= =
=
cm h
t
23 =
18
2
1
1
05 . 707
5
23
6 . 330
cm A
h
h
A A
t
c
=
=
=
) 6 . 330 (
2
2
cm A =
cm d sprue of diameter Bottom
cm d sprue of diameter Top
52 . 20 ) (
05 . 30 ) (
2
1
=
=
19
Volume of riser =3*0.065*290
56.55cm3
Here we use two riser so volume of each riser
is 29 cm3
Cylendrical riser so dia of riser is 3.3 cm
20
Area of cylender =
21
Calculation for Riser Design
Calculation for the diameter of Riser :
Area of Riser (cylindrical) =
riser of volume
riser of Area
casting of volume
casting of Area
= (X) ratio Freezing
2
3 . 3
2
3 . 3 * 3 . 3 *
[
+ [
22
So the area of cylender is 51.31cm3
Volume of riser dh =28.22
Since using Blind Riser (Height to diameter
ratio)= 1:1
means ,
D h
r
=
D
D
D
X
D h D riser of Volume
D D D riser of Area
r
0219 . 0
785 . 0
39 . 3
81 . 163100
876 . 17901
785 . 0
4
93 . 3 78 . 0 14 . 3
3
2
3 2
2 2 2
= =
=
[
=
= + =
23
By using Empirical relation for freezing Ratio :
where , a, b & c are constant
a, b & c values for Aluminium ,
a = 0.10
b = 0.06
c = 1.08
c
b Y
a
X +
=
3 4
3
10 4272 . 1
5500
785 . 0
D
D
volume casting
volume riser
Y
= = =
24
.) ( 25 . 12
.) ( 25 . 12
,
0 11264 420 49
08 . 1
06 . 0 10 427 . 1
10 . 0
0219 . 0
) (
3 4
3 4
approx cm riser of height
approx cm D
method error trialand By
D D D
D
D
X ratio f reezing
=
=
=
+
=
=
25
FINAL DIMENSIONS OF
GATING SYSTEM
1 CHOKE AREA = 330.6 cm
2 CHOKE DIAMETER = 20.52 cm
3 SPRUE UPPER DIA = 30.05 cm
4 SPRUE BOTTOM DIA = 20.52 cm
5 RUNNER WIDTH = 31.4 cm
6 VELOCITY OF SPRUE INLET = 99.045 cm/sec
7 VELOCITY OF SPRUE EXIT = 21.65 cm/sec
8 RUNNER EXTENSION =62.8 cm
26
References
http://www.mechlook.com/2010/04/pattern-and-
pattern-allowances/, date: 5 oct. 2011
http://www.brtechnocast.com/, date: 7 oct. 2011
www.2hoffshore.com/documents/papers/pap034.p
df, 2oct 2011
Malik and Ghosh, Manufacturing Science
P.N.Rao, Manufacturing Technology.
T.V Raman Rao,Metal casting.
27
THANK YOU
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