GatingSystem

Themetalflowsdownfromthepouringbasinorpouringcupintothedowngateorsprue Downgatesorsprue Crossgatesorrunners andpassesthroughthecrossgateorchannelsandingatesorgatesbeforeenteringintothe Ingatesorgates

.y tv ac d o m i l

Figure 17: Schematic of Gating System

GoalsofGatingSystem Thegoalsforthegatings stemare y Tominimizeturbulencetoa oidtrappinggassesintothemold v Togetenoughmetalintothemoldca it beforethemetalstartstosolidif v y y

GATING SYSTEM Theassembl ofchannelswhichfacilitatesthe

moltenmetaltoenterintothemoldca it

y y y

Downgatesorsprue Crossgatesorrunners Ingatesorgates

Toa oidshrinkage Establishthebestpossibletemperaturegradientinthesolidif ingcastingsothat theshrinkageifoccursmustbeinthegatings stemnotintherequiredcastpart Incorporatesas stemfortrappingthenon-metallicinclusions

HydraulicPrinciplesusedintheGatingSystem Reynold'sNumber Natureofflowinthegatings stemcanbeestablishedb calculatingRe nold's number

RN V D m r

= = = = =

Re nold'snumber MeanVelocit offlow diameteroftubularflow KinematicsViscosit Fluiddensit =D namic iscosit /Densit

WhentheRe nold'snumberislessthan2000streamlineflowresultsandwhen thenumberismorethan2000turbulentflowpre ails Asfaraspossiblethe turbulentflowmustbea oidedinthesandmoldasbecauseoftheturbulence sandparticlesgetsdislodgedfromthemoldorthegatings stemandma enter intothemouldca it leadingtotheproductionofdefecti ecasting Excess turbulencecauses Inclusionofdrossorslag Airaspirationintothemold Erosionofthemoldwalls Bernoulli'sEquation

h P

= = = g r = =

heightofliquid StaticPressure metal elocit Accelerationduetogra it Fluiddensit

Turbulencecanbea oidedb incorporatingsmallchangesinthedesignof gatings stem Thesharpchangesintheflowshouldbea oidedtosmooth changes Thegatings stemmustbedesignedinsuchawa thatthes stem alwa srunsfullwiththeliquidmetal Themostimportantthingstorememberin designingrunnersandgatesaretoa oidsharpcorners An changesindirection orcrosssectionalareashouldmakeuseofroundedcorners Toa oidtheaspirationthetaperedspruesaredesignedinthegatings stems A spruetaperedtoasmallersizeatitsbottomwillcreateachokewhichwillhelp keepthespruefullofmoltenmetal TypesofGatingSystems(Figure18a,18b) Thegatings stemsareoftwot pes: Pressurizedgatings stem Un-pressurizedgatings stem PressurizedGatingSystem Thetotalcrosssectionalareadecreasestowardsthemoldca it Backpressureismaintainedb therestrictionsinthemetalflow Flowofliquid( olume)isalmostequalfromallgates Backpressurehelpsinreducingtheaspirationasthespruealwa sruns full Becauseoftherestrictionsthemetalflowsathigh elocit leadingtomore turbulenceandchancesofmolderosion Un-PressurizedGatingSystem Thetotalcrosssectionalareaincreasestowardsthemoldca it Restrictiononl atthebottomofsprue Flowofliquid( olume)isdifferentfromallgates

aspirationinthegatings stemasthes stemne errunsfull Lessturbulence

Fig 18a : Pressurized Gating System

Fig 18b : Un-Pressurized Gating System

TypesofGatingSystemsRiser Riserisasourceofextrametalwhichflowsfromrisertomoldca it to compensateforshrinkagewhichtakesplaceinthecastingwhenitstarts solidif ing Withoutariserhea ierpartsofthecastingwillha eshrinkage defects,eitheronthesurfaceorinternall Risersareknownb differentnamesasmetalreser oir,feeders,orheaders Shrinkageinamold,fromthetimeofpouringtofinalcasting,occursinthree stages 1 duringtheliquidstate 2 duringthetransformationfromliquidtosolid 3 duringthesolidstate Firstt peofshrinkageisbeingcompensatedb thefeedersorthegating s stem Forthesecondt peofshrinkagerisersarerequired Risersarenormall placedatthatportionofthecastingwhichislasttofreeze Arisermuststa in liquidstateatleastaslongasthecastingandmustbeabletofeedthecasting duringthistime FunctionsofRisers Pro ideextrametaltocompensateforthe olumetricshrinkage Allowmoldgasestoescape Pro ideextrametalpressureonthesolidif ingmoldtoreproducemold detailsmoreexact DesignRequirementsofRisers 1 Risersize:Forasoundcastingrisermustbelasttofreeze Theratio of( olume/surfacearea)2oftherisermustbegreaterthanthatofthecasting Howe er,whenthisconditiondoesnotmeetthemetalintherisercanbekept inliquidstateb heatingitexternall orusingexothermicmaterialsintherisers

2 Riserplacement:thespacingofrisersinthecastingmustbe consideredb effecti el calculatingthefeedingdistanceoftherisers 3 Risershape:c lindricalrisersarerecommendedformostofthe castingsassphericalrisers,althoughconsidersasbest,aredifficulttocast To increase olume/surfacearearatiothebottomoftherisercanbeshapedas hemisphere