Professional Documents
Culture Documents
Q = v1 A1 = v2 A2
– Q = volumetric flow rate, m3/s
– v = velocity, m/s
– A = Cross sectional area of the liquid, m2
A1/ A2 = √ (h2/h1)
Fundamentals of metal casting
Fluid Flow
If the liquid level has reached a height of x at the gate, then the
gate velocity is
v = c √ {2g (h-x)}
• The flow rate through the gate will be the product of this
velocity and the gate area according to Mass Continuity
equation
• The shape of the casting will determine the height as a
function of time
• Mold Filling Time = casting volume /mean flow rate = V/ Q
– V = Volume of mold cavity, m3
– Q = Volume flow rate, v x A, m3/s
Fundamentals of metal casting
Flow Characteristics (Reynolds number)
• presence of turbulence (as opposed to the laminar flow) in
fluid flow in gating systems
• Turbulence is flow that is highly chaotic => aspiration in
casting systems
• Reynolds number, Re, (ratio of the inertia to the viscous
forces) is used to quantify presence of turbulence
• v = velocity of the liquid
• D = diameter of the channel
• = density of the liquid
• = viscosity of the liquid
Re < 2000 = Laminar flow
2000<Re<20000 = Mixture of laminar and turbulent flow - Harmless
Re > 20000 = Turbulent flow – Air entrainment and formation of dross/slag (the
scum that forms on the surface of molten metal) from the reaction of the liquid
metal with air and other gases <= vacuum casting, using properly designed
pouring basins and runner systems, using filters (ceramics, mica, or fiberglass)
Fundamentals of metal casting
Solidification Time
• During the early stages of
solidification, thin skin
begins to form at the
relatively cool mold walls,
• as time passes, thickness
of the skin increases
• With flat mold walls, this
thickness is proportional
to square root of time
• Thus, doubling the time
will make skin √2 = 1.41
times or 41% thicker
Fundamentals of metal casting
Solidification Time
• The solidification time is a function of the volume of a casting and its
surface (Chvorinov’s rule)