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Numerical Analysis of Mould Filling and Gating Design for Aluminium Mould Castings
Article (PDF Available) in Journal of Applied Sciences Research · December

2015 with 69 Reads
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P Siva
Babu Bhaskaran
17.37 · RATHINAM TECHNICAL CAMPUS,COIMBATORE,INDIA
Dr. Dharmalingam S
18.79
Abstract
A fuzzy logic based optimization is applied to obtain an optimal design of a typical gating system used for the gravity process to produce aluminum parts.
This represents a novel application of coupling fuzzy logic techniques with a foundry process simulator, and it is motivated by the fact that a scienti cally
guided search for better designs based on techniques that take into account the mathematical structure of the problem is preferred to commonly found trial-
See all › approaches.
and-error See all
The› simulator applies the nite volume method and the VOF algorithm for CFD analysis. The technique was usedDownload
to solve 3D gatingPDF
full-text
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8 References
system 5 Figures
design problems using two design variables. The results clearly show the effectiveness of the proposed approach for nding high quality castings
when compared with current industry practices.
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Copyright © 2015, American-Eurasian Network for Scientific Information publisher
JOURNAL OF APPLIED SCIENCES RESEARCH
ISSN: 1819-544X EISSN: 1816-157X
JOURNAL home page: http://www.aensiweb.com/JASR 2015 November; 11(22):pages 5-11.

Published Online 25 November 2015. Research Art icle
Numerical Analysis of Mould Filling and Gating Design for Aluminium Mould
Castings
1 P. Siva, 2B. Babu and 3 S.Dharmalingam
1 Assistant Professor, Nehru Institute of technology, Department of Mechanical Engineering, Coimbatore 641105, INDIA
2 Assistant Professor, Rathinam Technical Campus, Department of Mechanical Engineering, Coimbatore 641121, INDIA
3 Professor & Dean, Rathinam Technical Campus, Department of Mechanical Engineering, Coimbatore 641121, INDIA
Received: 23 October 2015; Accepted :23 Novemb er 2015
© 2015 AENSI PUBLISHER All rights reserved

See all › See all › ABSTRACT Download full-text PDF
A fuzzy logic based optimization is applied to obtain an optimal design of a typical gating system used for the gravity process to
produce aluminum parts. This represents a novel application of coupling fuzzy logic techniques with a foundry process simulator, and it is
motivated by th e fact that a scientifically guided search for better designs based on techniques that take into account the mathematical
structure of the problem is preferred to c ommonly found trial-and-error approaches. The simulator applies the finite volume method and
the VOF algorithm for CFD analysis. The techn ique was used to solve 3D gating system design problems using two design variables. The
results clearly sho w t he effectiveness of the proposed approach for finding high quality castings when compared with current industry
practices.
Keywords:
INTRODUCTION packages for casting simulation and analysis. These

packages are grid-based and employ the volume-of-
Gravity die casting (GDC) processes are fluid method. In the die casting community, a
capable of making complicated high integrity popular commercial software package for
components,such as wheels, cylinder heads, engine simulating mould filling is MAGMAsoft and
blocks and brake callipers, at lower cost than most Smoothed particle hydrodynamics (SPH) is a
other casting methods. Cycle times for gravity die Lagrangian method (Monaghan, 1992) and does not
casting are shorter than for the sand casting process require a grid. It is suited for modelling fluid flows
leading to larger quantities of castings produced per that involve droplet formation, splashing and
unit time. Surface finish and internal quality complex free surface motion.
(particularly pertaining to porosity) are also better The simulation will describe the casting
using the GDC process. Improvements to both process by using volume of fluid (VOF) model
product quality and process productivity can be integration with the solidification model in Fluent.
brought about through improved die design. These A numerical optimization technique based on
include developing more effective control of the die gradient-search is applied to obtain an optimal
filling and die thermal performance. design of a typical gating system used for the
Numerical simulation offers a powerful and cost gravity process to produce aluminum parts.
effective way to study the effectiveness of different Casting processes involve filling of molten metal in a
die designs and filling processes. For such mould and its solidification by withdrawal of heat.
simulations to be useful, their accuracy must first be Filling and solidification involve rapidly growing
assessed. There are a number of available software metal/air free surface and liquid/solid interface
Corresponding Author: P. Siva , Assistant Professor, Nehru Institute of technology, Department of Mechanical
Engineering, Coimbatore 641105, INDIA
6 P. Siva and B. Babu, 2015 /Journal Of Applied Sciences Research 11 (22), November, Pages:5-11
within the solidifying domain, which makes the the design of the gating system can be an advantage.
overall process experimentally difficult to visualize. The hydraulic factors that affect the flow of molten
Therefore, use of numerical simulations to analyze metals are: (a) Bernoulli’s Theorem, (b) Law of
and control the solidification parameters related to Continuity, (c) Momentum Effects, (d) Frictional
fluid flow and heat transfer is desirable. This analysis Forces, and (e) Reynolds Number. In the past
is very useful to improve the quality of the casting. decades some equations based on empirical
One of the key elements to make a metal casting relationships have been derived and used to design a
of high quality is the design of a good gating system. gating system after applying these relationships, a
The gating system refers to those channels through gating system of questionable quality is obtained.
which the metal flows from the ladle to the mold Typically modifying the mold geometry by applying
cavity. The use of a good gating system is even more trial-and-error approach, a better gating system is
important if a casting is produced by a gravity obtained. However, this trial-and-error approach
process. If poor gating techniques are used, costs time and money. The aim of this project is to
invariably, lower casting quality is achieved, because investigate the effects of gating system on mould
of damage on the molten metal received during the filling in casting process and to formulate the
flow through the gating system .It could be even alternative procedure to optimize the gating system
worse, if the molten material is a sensitive metal for with the use of computer aided numerical simulation
receiving damage during the filling, because of dross techniques.
and slag formation.
The aluminum and their casting alloys are Magma Soft:
considered in this category. Aluminum alloys are MAGMA soft is a 3D solidification and fluid
very reactive to oxygen and form an oxide, Al 2O .3 flow package used in the die casting industry to model
When flow is smooth, this oxide tends to form and the molten metal flow and solidification in dies.
remain on the surface of the stream. However, when MAGMAsoft employs the finite difference method
flow is turbulent, the oxide goes into the molten to solve the heat and mass transfer on a rectangular
metal stream and may carry gas or air bubbles with grid. It is a useful tool for simulating molten metal
it. The oxides remain on the turbulent flow without flow in a permanent mould since it can provide
flotation, because their densities are similar to useful information aboutthe filling pattern. It also
aluminum. Then, to avoid damage to the molten produces reasonably accurate data on casting-related
See all › aluminum,
See all › the gating system must be designed to featuresDownload
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as premature
Share solidification,air
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8 References eliminate
5 Figures the air by avoiding conditions which permit entrapment, velocity distribution, runner and gate
aspiration due to formation of low pressure areas. effectiveness. MAGMAsoft, however, has some
Keeping the speed of the molten aluminum below of limitations. The rectangular grid artificially
0.50 m/s and a smooth stream is equally important. introduces staircases along curved and sloping
In order to achieve a good gating system design, boundaries and the VOF formulation for modeling
it is necessary to start following basic principles. the free surfaces leads to artifical diffusion and mass
Molten metals behave according to fundamental conservation problems in these region.
hydraulic principles .Applying those fundamentals to
Table I: Mold Dimensions are in mm.

Axis X Y Z
Sprue Entrance 15 19.2 ─
Sprue Exit 15 5 ─
Sprue Height ─ ─ 380
Well 15 5 10
Runner 15 240 20
Gate 10 60 15
Plate 10 200 100
Computational Fluid dynamics (CFD): simulation scenario.

Computational fluid dynamics, usually The fundamental basis of almost all CFD
abbreviated as CFD, is a branch of fluid problems are the Navier–Stokes equations, which
mechanics that uses numerical define any single-phase (gas or liquid, but not both)
methods and algorithms to solve and analyze fluid flow. These equations can be simplified by
problems that involve fluid flows. Computers are removing terms describing viscous actions to yield
used to perform the calculations required to simulate the Euler equations. Further simplification, by
the interaction of liquids and gases with surfaces removing terms describing vorticity yields the full
defined by boundary conditions. With high- potential equations. Finally, for small perturbations
speed supercomputers, better solutions can be in subsonic and supersonic flows (not transonic or
achieved. Ongoing research yields software that hypersonic) these equations can be linearized to yield
improves the accuracy and speed of complex the linearized potential equations.
Fig. 1: Dimensions of rectangular cavity (mm).
The Experimental Setup: Smith ells Metals Reference Book gives the dynamic
The overall geometry of the casting—a simple viscosity of pure aluminum at the freezing point as
plate with a simple bottom-gated running system 1.3 x 10 -3 Pa ·s and its density as 2.385 x 10 3 kgm-3.
(and no feeder)—is depicted by Figure 1 and Table I. This yields a kinematic viscosity of 0.55 x 10-6 m 2/s.
The mold was made from 60 AFS-grade
washed-and-dried silica sand, bonded with 1.2 wt.% X-Ray Radiography:
phenolic urethane resin (Ashland Pepset). Mold filling was observed with a 160 kV x-ray
This is a widely used molding material, and it was source (1.5 mm diameter) equipped with an image
hoped that good material properties would be intensifier. Recording was performed using a VHS 50
available. The choice of a sand mold assisted the Hz recorder. Pouring in the lead-lined cabinet was
See all › viability
See all › of analysis by x-ray radiography and carried out remotely, outside the cabinet, byfull-text
an PDF
8 References
simplified
5 Figures
computation to some extent because i ts operatorDownload
viewingcitation
the pour
Share via a Download
closed-circuit
high permeability to air would reduce the back television camera.
pressure to a minimum due to entrapped mold gas. The instant when the stopper was lifted was
The liquid metal used was 99.999% aluminum; again, designated as time zero. Subsequently, x-ray video
this choice was made in order to obtain unambiguous frames were taken at 0.02 s intervals during filling.
and accurate material data. The experiment was repeated several times. In Figure
2, three sequences are shown. The figure presents
Mold Material: video excerpts at 0.25 s intervals during the filling of
The materials data for pure aluminum were three separate castings to ascertain the degree of
taken from Metals Handbook, Rolls Royce, reproducibility of the pour. The researchers were
MagmaGmbh, and others.. These were a wide careful to ensure that the experimental conditions in
freezing range, which indicated that the data applied e ach case were reproduced as exactly as possible.
more accurately to commercially pure aluminum The only difference in the sequences is that the
(99%) than the pure material intended for the geometry of the view was changed slightly so as to
experiment. the viscosity of liquid aluminum, which see the sprue on one occasion and the ingate area and
was quoted as a number (4 x 10 -6) without units. end of the runner on the other occasions.
Fig 2: Three experiments run on the real- time x-ray unit to compare the progressive filling of
the mold: (a) 0.24 s after stopper removal, (b) 0.5 s, (c) 0.74 s, (d) 1.0s, (e) 1.24 s, (f) 1.5 s, (g)1.74 s, and (h)
2.0 s.
Problem Definition: In this work the runner depth (ZL) and slope of
The physical system for the present work the gate (CX) are varied and its effects on the mold
consists of a rectangular mould of height 100 mm filling is to be studied. After doing various analysis
and width 200 mm. A schematic representation of the the optimum values are find out using optimization
physical system is shown in Fig 3. Aluminium enters technique by using fuzzy logic.
through the mould through the sprue.
Fig. 3: Gate design parameters ZL and CX.
Methodology:
In all of these approaches the same basic procedure is followed.
During preprocessing: the initial conditions are also defined. The simulation
The geometry (physical bounds) of the problem is started and the equations are solved iteratively as a
is defined. The volume occupied by the fluid is steady-state or transient. Finally a postprocessor is
divided into discrete cells (the mesh). The mesh may used for the analysis and visualization of the
be uniform or non-uniform. The physical modeling is resulting solution.
defined – for example, the equations of motion +
enthalpy + radiation + species conservation Procedure for Optimization:
Boundary conditions are defined. This involves After post processing the validation has done with
specifying the fluid behaviour and properties at the the experimental work as shown in fig no 6.
boundaries of the problem. For transient problems,
Optimization model description

Table 2:
Analysis No ZL CX
1 9.5 0.3
2 9.5 0.9
3 9.5 1.5
4 10.25 0.3
5 10.25 0.9
6 10.25 1.5
7 10.9 0.3
8 10.9 0.9
9 10.9 1.5
Fig. 4:
For the present problem, the following two design variables and the step size parameter are
formulation was used. shown in Table no 2.
Design of experiments has conducted.Out of the 9
Design variables: values the optimum gate design has obtained through
ZL_- runner depth (mm), optimization technique. For that fuzzy logic used by
CX -_ slope on the tail(mm). writing rules for getting effective velocity at the
See all › See all › ingate.
Parameters: Download citation Share Download full-text PDF
8 References ZLl -_ lower
5 Figures limit of the runner depth (mm), Model I:
ZLu- _ upper limit of the runner depth (mm), Experimentally at selected time instances are
CXl -_ lower limit of slope on the tail(mm), compared. In the experimental images, the number
CXu -_ upper limit of slope on the tail(mm). at the bottom left corner is the time in seconds.
The filling process for Model 2 is somewhat similar
Auxiliary variables: to that of Model 1 in that the early part of die filling
tci -_ filling time of element i of the runner; (s), is dominated by sloshing free surface wave
tej -_ filling time of element j of the ingate (s), motion. This sloshing motion is damped after a
V xj -_ x-component of the aluminum velocity in the certain time. We thus restrict our discussion to the
jth ingate element; (m/s), early part of the die filling when the process is much
V yj -_ y-component of the aluminum velocity in the more dynamic.
jth ingate element; (m/s), At 0.24 s, the large rectangular section of the
V zj -_ z-component of the aluminum velocity in the cavity is just starting to fill. In that simulations shows
jth ingate element (m/s), the red color is metal,blue color is air.
Vj _- objective function that represents the aluminum At 0.5 s, the metal reached to the ingate at both
velocity at the jth ingate element. experimental and simulation condition.
At 0.74 s,the amount of metal filling has entered
Formulation: into the cavity with high velocity.
Minimize Vj (ZL, CX) = √Vxj 2 + Vyj 2 + Vyz2 At 1.24 s, tbe amount of metal is filling and
spread over horizontally whereas vertical direction of
Subject to: flow in fluent.
 tci < tej At 1.74 s. the flow of metal almost completed
 ZLl < ZL < ZLu has turbulent flow at both condition.
 CXl < CX < CXu At 2 s,the metal gets filled completely inside
the rectangular cavity in both models.
Design of Experiments (DOE):
For the experimental design (DOE), an L9 array Results:
were used. The complete set of analysis included 09 For the effective mold filling and optimized
executions using 2 factors at 3 levels each (3 2 = 09). gating design can be achieved through CFD package.
The values used for the starting solution values of the Then the Design of experiments conducted with L9
10 P. Siva and B. Babu, 2015 /Journal Of Applied Sciences Research 11(22), November, Pages:5-11
array and number of trials taken then its applied to medium and high level condition.
fuzzy logic by writing rules for 9 values at low,
Fig. 5:
The optimized value of inlet velocity at an average value of 39.4m/sec.

The optimum value of runner tail slope is 0.85 mm .
The optimum value of runner depth is 10.2mm.
Fig. 6: Filling of Model 1. Left: Experiment. Right: Fluent Software.
Conclusion: Otherwise the bubble will form.

In this paper, Apart from the trial and error • The optimum velocity has attained to the ingate
approach, this numerical simulation results will for an effective mold filling. Further the
give effective mould filling and solidification. The solidification area can concentrate for the change of
experiment and both numerical methods is good with heat transfer through MAGMA or Fluent.
each being able to predict the overall structure of • MAGMA software is more reliable and used in
the filling process. big industries but the same time the software is too
• The simulation results of cavity filling are costly to use. Such that small scale industry Fluent
validated with the experimental work by the use of can use.
Fluent. • Further experiment can conduct with the
• Design of experiments conducted with L9 array. optimized value and compared with the simulation
• Condition followed that the time of filling of the work.
runner should be first than the ingate filling time.
11 P. Siva and B. Babu, 2015 /Journal Of Applied Sciences Research 11(22), November, Pages:5-11
References ”Modelling Simul. Mater. Sci. Eng. 13: 903–

917.
1. Nitin Pathak, Arvind Kumar, Anil Yadav, Pradip 6. Lee, B.D., U.H. Baek and J W Han, 2011.
Dutta, 2009. “Effects of mould filling on ”Optimization of gating design for die casting of
evolution of the solid–liquid interface during thin magnesium alloy based multi cavity LCD
solidification” , Elsevier, Applied Thermal housings” Springer, ASM International, 1059-
Engineering, 29: 3669–3678. 9495.
2. Sergey, V., Shepel, Samuel Paolucci, 7. Masoumi, M., H. Hu, 2005. ”Effect of Gating
“Numerical Analysis Of Filling And Design on Mold Filling” AFS Transactions,
Solidification Of Permanent Mould Castings” Paper, 05-152(02): 1-12.
Elsevier,USA. 8. Tresna Priyana Soemardi,Johny Wahyuadi
3. Ik-Tae Im a, Woo-Seung Kim B. C. Kwan-Soo Soedarsono,Rianti Dewi Sulamet-
Lee, 2000.”A unified analysis of filling and Ariobimo,2001,”The Role Of Casting Flow And
solidification in casting with natural convection” Solidification Simulation For The Improvement
Elsevier, Heat and mass transfer, 44: 1507-1515. Of Thin Wall Ductile Iron Quality”.
4. Sirrell, B., M. Holliday and J. Campbell, 2005. 9. HA, J. and P. Cleary, 1999. “Comparison of SPH
“Benchmark testing the flow and solidification simulations of high pressure die casting with
modeling of Aluminium castings”. theexperiments and VOF simulations of Schmid
5. Attar1, E., P. Homayonifar2, R. Babaei3, K. and Klein”,Int. J. Cast Metals Res., submitted.
Asgari3 and P. Davami1, 2006.” Modelling of 10. MONAGHAN, J.J., 1992. “Smoothed
air pressure effects in casting moulds particle hydrodynamics”, Ann. Rev. Astron.
Astrophys., 30: 543- 574.
SeeCitations (0)
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› Download full-text PDF
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Copyright © 2015, American-Eurasian Network for Scientiﬁc Information publisher

JOURNAL OF APPLIED SCIENCES RESEARCH

ISSN: 1819-544X EISSN: 1816-157X

JOURNAL home page: http://www.aensiweb.com/JASR 2015 November; 11(22):pages 5-11.

Received: 23 October 2015; Accepted :23 Novemb er 2015

© 2015 AENSI PUBLISHER All rights reserved

INTRODUCTION packages for casting simulation and analysis. These

Table I: Mold Dimensions are in mm.

Computational Fluid dynamics (CFD): simulation scenario.

Fig. 1: Dimensions of rectangular cavity (mm).

Fig. 3: Gate design parameters ZL and CX.

Optimization model description

The optimized value of inlet velocity at an average value of 39.4m/sec.

Fig. 6: Filling of Model 1. Left: Experiment. Right: Fluent Software.

Conclusion: Otherwise the bubble will form.

References ”Modelling Simul. Mater. Sci. Eng. 13: 903–

View Show abstract

Benchmark testing the ow and solidi cation modeling of AI castings

View Show abstract

View Show abstract

View Show abstract

Numerical simulation of lling and solidi cation of permanent mold castings

View Show abstract

Electrochemical Micro Machining

Synthesis and Characterization of Al-Al2o3 Composites

Experimental Investigations On Al/Sic/ B4c Composites Using Electro Chemical Micro

Last Updated: 30 Apr 18

News Help center Recruiting

OHAUS - Laboratory Equipment

us.ohaus.com/laboratory Visit Site

© ResearchGate 2018. All rights reserved. Imprint · Terms · Privacy

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