Foundry Methoding 2022

Foundry Methoding
DISCLAIMER: THIS IS SOLELY FOR TEACHING PURPOSE; NOT TO BE SHARED.

 GATING SYSTEM DESIGN
 RISER DESIGN
 CHILL DESIGN
 EXOTHERMIC PAD
 CASTING YIELD---
 PHYLOSOPHY: DIRECTIONAL SOLIDIFICATION; DEFECT FREE CASTING

Elements of Gating System
• The passage and components through which molten metal

Enter the mould cavity
 Pouring Basin
 Sprue
 Sprue well
 Runner
 Ingate
 Riser
Purpose of Gating System
 Mould should be completely filled with smallest time

 Metal should flow smothly without terbulent flow
 Slag should not be allowed to enter
 Controlled flow
 Thermal Gradient
 Prevent Mould erosion
 Should be economical and easy to implement
 Casting Yield should be maximum
 1.Avoid turbulent entrainment 2. Avoid laminar entrainment of the surface film 3.

Avoid bubble damage 4. Avoid shrinkage damage. 5. Avoid core blow
 . CRITICAL VELOCITY TO PREVENT TURBULENT ENTRAINMENT
 𝑅𝑒 = 𝑣𝜌𝑑/v, . Weber number is obtained from a comparison of the inertial pressure and surface tension pressure and is expressed
as: 𝑊𝑒 = 𝑣 2𝜌𝑟/gema
 𝑣𝑐𝑟𝑖𝑡 = 2(𝛾/𝑟𝜌) 0.5
[𝑣 is the velocity of the molten metal of density 𝜌, viscosity 𝜈, and surface tension 𝛾 The term, 𝑑 is the characteristic dimension of the
flow path of the liquid. The term 𝑟 is the radius of curvature of a hemispherical surface deformation]
 Researches have shown that the critical velocity for light metals is about 5.5m/s and for dense metals such as copper and ferrous
alloys, the critical velocity is about 4.5m/s. Generally, a Weber number of 0.2 to 0.8 is acceptable
Controlling Factor
 Pouring Basin Design
 Fluidity Of Melt
 Pouring Rate
 Sprue---Area
 Runner---Area, No.
 Ingate--- No, Size, Position, Area

Components of Gating System
 Melt-Atmosphere
reaction
 Prevent entrapment
 Prevent entrainment
 Prevent Turbulence
 Entrainment of biofilms
 It is desirable to convey the
molten metal in a non-
turbulent manner into all parts
of the mold cavity
 T second pouring Basin
Pouring Basin Design

Design of the Components of Gating System
 Calculate Pouring Time based on---t=
K= Constant, W= Casting Weight
 Calculate Pouring Rate
 Pouring Velocity
 Apply Bernoullis Theorem
 Continuity Equation
Source: https://www.slideshare.net/aslam1992/u3-p1-gating-system
Source: https://www.slideshare.net/93Bhardwaj/gating-system-in-casting
Production sand casting
https://www.scribd.com/document/397270492/MIT-Casting-Processes-pdf
16
Mold Filling
Bernouli’s Equation:
p v2
h   Const .
pg 2g
h
Reynold’s Number:
vDP
Re 

•Short filling times
•Potential Turbulence
(see p. 273 … Kalpakjian
https://www.scribd.com/document/397270492/MIT-Casting- 17
Mold Filling Example (1 of 2)
18
Mold Filling Example (2 of 2)
19
Design of Riser, Chill, Exothermic Pad to provide
Directional Solidification, and Prevent solidification shrinkage
Riser Position, Size, Type of Riser, No. of Riser
 Open Riser and Blind Riser

 Top or Side Riser
 Different methods for design of riser….

 Modulus Method---- M (R ) = 1.2 M (C)
 Caine’s Method---
 NRL Method…
 Riser Feeding Distance--- L= F x D

Phase
Change &
Shrinkage
https://www.scribd.com/document/397270492/MIT-Casting-Processes-pdf 24
Solidification of a binary alloy
25
Composition change during solidification
26
Solidification
27
Heat Transfer – Sand Casting
2
V 
ts   
 A
28
Heat Transfer – Die Casting
1
V 
ts   
 A
Steady State Conduction Heat Transfer
Figure 1
30
Steady State Conduction Heat Transfer
Figure 2
31
Thermal Conductivity “k” of Various Materials for Parts and
Molds (W/m °K)
Copper 394
Aluminum 222
Iron 29
Sand 0.61
PMMA 0.20
PVC 0.16
dT
q  k
dx
Film Coefficients W/m2°K
Typical die casting 5,000

Natural convection 1 - 10
Flowing air 10 - 50
q   hT 
33
Transient Heat Transfer
34
Sand Casting (see Flemings)
Sand Casting (see Flemings)
Solidification Time
enthapy
Use Flemings
result here
37
Solidification Time (cont.)
38
Cooling Time; thin slab
Cooling time;intersection
  
V h 1  1 
 1   
A 2 2  L  1 
 

  h 
CHILL DESIGN
 CHILL POSITION
 CHILL CONTRIBUTION
 Chill Design to promote directional solidification

 To promote shrinkage towards riser
 Chill thickness---D= K.T
 Chill Position
Exothermic Mixture or Pad to Keep Metal molten for long time
Casting Defects
Solidification Related Defects
 Gas Porosity
 Shrinkage Porosity
 Hot Tear
 Cold Crack
 Segregation
“ 10 Rule of Good Casting Design”
 Use good quality melt

 “Avoid Turbulence entrainment
 Avoid Laminar entrainment of surface film
 Avoid bubble damage
 Avoid core blow
 Avoid Shrinkage damage
 Avoid Convection Damage
 Reduce Segregation Damage
 Reduce Residual stress
 Provide Location Point
Properties of Casting
 Test Bar
 The Statistics of Failure

 Weiball Analysis
 Effect of Defect
 Mechanical
 Chemical and Electrochemical
 Surface finish
 Pressure Tightness
 Quality Indices
FOUNDRY METHODING---CASE STUDY

Foundry Methoding 2022

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Foundry Methoding 2022

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Foundry Methoding

DISCLAIMER: THIS IS SOLELY FOR TEACHING PURPOSE; NOT TO BE SHARED.

 PHYLOSOPHY: DIRECTIONAL SOLIDIFICATION; DEFECT FREE CASTING

• The passage and components through which molten metal

 Mould should be completely filled with smallest time

 1.Avoid turbulent entrainment 2. Avoid laminar entrainment of the surface film 3.

 . CRITICAL VELOCITY TO PREVENT TURBULENT ENTRAINMENT

 Pouring Basin Design

 Ingate--- No, Size, Position, Area

 T second pouring Basin

Pouring Basin Design

 Calculate Pouring Time based on---t=

K= Constant, W= Casting Weight

 Calculate Pouring Rate

 Apply Bernoullis Theorem

 Open Riser and Blind Riser

 Different methods for design of riser….

 Riser Feeding Distance--- L= F x D

Typical die casting 5,000

Solidification Time (cont.)

 Chill Design to promote directional solidification

 Use good quality melt

 The Statistics of Failure

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