Gating design

Casting technology

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 1

Gating design

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 2

Gating design
• Gating are flow passages to run and fill molten metal in mould
cavity.
• Gating system include distribution of clean metal with proper
rates and velocities at specific location in the mould.
• Top gate
• Bottom gate
• Horn gate
• Parting type
21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 3
Gating design

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 4

Gating design

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 5

Gating design

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 6

Gating design

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 7

Gating design
• Pressurized gating system
• More yield
• Turbulent flow

• Unpressurized gating system

• Less yield
• Laminar flow

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 8

Gating design

Gating
design

Sprue Runner Ingate

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 9

Gating design
• Gating ratio

• CSA of sprue : CSA of Runner : CSA of Ingate

• AS : AR : A G

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 10

Gating design

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 11

Gating design
• Assume
• AS : AR : AG (Gating ratio)
• [Link] - for cast iron
• 1 : 2 : 1.5 – for steel
• 1 : 1 : 1 – for Al
• Density of steel – 7.8 X 10 -3 kg/cm3
• Density of steel – 7.2 X 10 -3 kg/cm3
21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 12
Gating design – Cast iron
• Step 1 : Calculation of casting weight
• Casting weight in kg = density of casting X volume of casting

• Step 2 : Calculation of pouring weight

• Pouring weight = Casting Weight / % yield
• Let % yield of Cast iron = 60 %
• % yield of Steel= 50 %

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 13

Gating design – Cast iron
• Step 3 : Calculation of pouring time

• Pouring time in seconds = 0.97 X 𝑃𝑜𝑢𝑟𝑖𝑛𝑔 𝑤𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝐾𝑔𝑠

• Step 4 : Calculation of choke area

• Choke area = Lowest CSA in the gating system
𝑃𝑜𝑢𝑟𝑖𝑔 𝑊𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝐾𝑔
• 𝐶ℎ𝑜𝑘𝑒 𝑎𝑟𝑒𝑎 =
1.1 𝑋 𝑝𝑜𝑢𝑟𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝑖𝑛 𝑠𝑒𝑐𝑜𝑛𝑑𝑠

• Choke area = Total ingate area

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 14

Gating design – Cast iron
• Step 5 : Calculation of ingate dimensions
𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑔𝑎𝑡𝑒 𝑎𝑟𝑒𝑎
• Area of each ingate=
𝑁𝑜 𝑓 𝑖𝑛𝑔𝑎𝑡𝑒𝑠

𝐿𝑒𝑛𝑔𝑡ℎ −2 ( 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑖𝑛𝑔𝑎𝑡𝑒𝑠)

• No of ingate =
𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑖𝑛𝑔𝑎𝑡𝑒𝑠

• For SG iron , W=4T

• For Grey cast iron, W = 3T

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 15

Gating design – Cast iron
• Step 6 : Calculation of runner dimensions
• If not specified in problem, assume no of ingates & runner = 2
(min)
• Total area of the runner = (8/3) X Choke area
𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑢𝑛𝑛𝑒𝑟
• 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑟𝑢𝑛𝑛𝑒𝑟 𝑏𝑎𝑟 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑢𝑛𝑛𝑒𝑟 𝑏𝑎𝑟𝑠

• Area of each runner = L X W

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 16

Gating design – Cast iron
• Step 6 : Calculation of runner dimensions
• Area of each runner = L X W
• For grey cast iron
• L=1.5 W for less than 50 kg pouring weight
• L=2 W for more than 50 kg pouring weight
• For SG iron
• L=2 W for less than 50 kg pouring weight
• L=2.5 W for more than 50 kg pouring weight
21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 17
Gating design – Cast iron
• Step 7 : Calculation of sprue dimensions
• Total area of the sprue = (4/3) X Choke area
• From total area of the sprue calculate the diameter of the bottom
diameter of the sprue

• Top diameter of the sprue = 2 𝑋 𝑏𝑜𝑡𝑡𝑜𝑚 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 18

Gating design – Cast iron
• Design a gating dimensions for a coal nozzle if the outer diameter is
60 cm, inside diameter is 40 cm and height is 300 cm. The distance
between ingates is 30 cm. The material is SG iron.

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 19

Gating design – Cast iron

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 20

Gating design – Cast iron

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 21

Gating design – Cast iron

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 22

Gating design – Cast iron

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 23

Gating design – Cast iron

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 24

Gating design – Cast iron

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 25

Gating design – steels
• Step 1 : Calculation of casting weight
• Casting weight in kg = density of casting X volume of casting

• Step 2 : Calculation of pouring weight

• Pouring weight = Casting Weight / % yield
• Let % yield of Cast iron = 60 %
• % yield of Steel= 50 %

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 26

Gating design – steels
• Step 3 : Calculation of pouring time
1
• Pouring time in seconds = 𝑆 𝑇𝐺 3 , where T = average thickness in mm,
G = pouring weight in kg,
• S = 1.3 for bottom gate, S = 1.4 for parting line gate, S = 1.5 for Top gate

• Step 4 : Calculation of choke area

𝐺
• 𝐶ℎ𝑜𝑘𝑒 𝑎𝑟𝑒𝑎 = , where ρ is density of liquid metal, C=0.9, t =
ρ𝑐𝑡 2𝑔𝐻

pouring time in seconds, g=981 kg/cm2 , H = effective height of the

metal.
21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 27
Gating design – steels
• Step 5 : Calculation of sprue dimensions
• Total area of the sprue = Choke area
• From total area of the sprue calculate the diameter of the bottom
diameter of the sprue

• Top diameter of the sprue = 2 𝑋 𝑏𝑜𝑡𝑡𝑜𝑚 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 28

Gating design – steels
• Step 6 : Calculation of runner dimensions
• Total area of the runner = 2 X Choke area (remember gating ratio)
• H=1.5W

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 29

Gating design – steels
• Step 7 : Calculation of ingate dimensions
• Total ingate area = 1.5 X choke area
• W=2T

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 30

Gating design – steels
• Design the gating dimensions for a steel casting for the
following dimensions of the casting, ( assume parting line
gating),
• L=2W, W=2T, casting weight = 12.6 kg, Average thickness =
6cm, effective height = 12cm.

21-10-2020 Krishnakumar K, Dept. Metallurgical Engg, PSGCT, CBE 31