Presentation of Mini Project on

Casting
Overview of Riser Design

Manish Kumar Paswan(2102006D) Under the Guidance of

Rahul Kumar Chourasia (2102014D) Prof. A R Ansari

Santosh Kumar Baraik (2102019D)

Prashant Sagar Oraon (2102013D)
Solidification of Casting
During solidification metal experience shrinkage which results in void formation.
This can be avoided by feeding hot spot during solidification.
Riser is used to feed casting during solidification.
 Risers
i. Risers are added reservoir design to feed liquid metals to the solidifying
casting as a means for compensating for solidification shrinkage.
ii. Risers must be solidify after casting .
iii. Riser should be located so that directional solidification occurs from the
extremities of mold cavity backward toward the riser .
iv. Thickest part of casting – last to freeze , Riser should feed directly to these
regions.
 Why risers ?
• The shrinkage occurs in three stages ,

1. When the temperature of liquid metal drops from pouring to freezing temperature.
2. When the metal changes from liquid to solid state and
3. When the temperature of solid phase drops from freezing to room temperature

• The shrinkage for stage 3 is compensated by providing shrinkage

allowance on pattern, while the shrinkage during stages 1and 2 are
compensated by providing risers.
The volumetric shrinkage of various metals and alloys are:-
 Riser location & Types

• Top riser

Riser located on the casting

Top riser Side Riser
• Side riser

Riser located next to the casting

• Blind risers

• Open riser

Blind Riser Open Riser

 Solidification time for casting
• Solidification of casting occurs by loosing heat from surface and amount of heat is
given by volume of casting .
• cooling characteristics of a casting is the ratio of surface area to volume.
• Higher the value of cooling characteristics faster is the cooling of casting
Chorine rule state that solidification time is inversely proportional to cooling
characteristics.

Solidification time t = K.(V/S)2

Where t = solidification time

K= mold constant
V= volume of casting
S= surface area
 IDEAL RISER
 (Cooling characteristic)riser should be minimum.
 So we can achieve it by S.A is minimum.
 We know that, for given volume sphere is having minimum surface area.
 Hence shape of riser should be spherical.

IDEAL CASE ACTUAL CASE

Methods Of Riser Design
• Following are the methods for riser design:

1.Caines Method

2.Modulus Method

3.NRL Method
Caine’s Method
According to Caine's if the casting solidifies very rapidly, the feeder volume need be only equal to the
solidification shrinkage of the casting.

Where , X= Freezing Factor

Y=Riser Volume/Casting Volume
a,b,c = constant

The freezing ratio, `X' of a mold is defined as the ratio of

cooling characteristics of casting to the riser.
Modulus Method
Modulus method is another method for finding the optimum riser size is the `modulus method.

Modulus is defined as the ratio of volume to surface area.

Modulus=Volume/Surface area

Where,
Volume of cylinder riser=πD3/4

Surface area = (πD2/4)+πD2

NRL Method(Naval Research Laboratory
Method)
NRL method is essentially a simplification of Caine’s method.
In this method shape factor is used in place of freezing ratio.

Shape Factor is equal to the sum of Length and

Width upon thickness.

S.F.=L+W/T
Methods of Riser Design

I) General Methods :
-This method is used when shrinkage volume of cating (vs) is given.

Step i) volume of shrinkage (vs) is to be calculated as per question

E.g :- shrinkage 3%
vs =3% of vc

Stepii) Riser volume (Vr)

Vr=3vs if nothing is mentioned

Stepiii) calculate dimension of riser by

Vr=π/4D2H {H and D relation will be given }

Stepiv) Compare the cooling characteristics.

(SA/V)r < (SA/V)casting => Accepted

(SA/V)riser > (SA/V)casting => failed because riser solidify first

Conclusion
It is concluded that the height of riser has great effect on the reduction of
shrink.
So we have to designed the riser by considering the height of the riser equals
to one and half times the diameter of the riser. By doing this we can get less
casting shrinkage in the casting process.