CASTING GATING
SYSTEMS
MADE BY
Dr. Sherif Mehanny
INTRODUCTIO
N main function of gating system is to lead clean
The
molten metal from ladle to the casting cavity
ensuring smooth, uniform and complete filling.
The flow of molten metal after being poured is a
transient phenomena accompanied by :
• Turbulence,
• Separation of the flow from the boundaries,
• Dividing and combined flow at the junction,
• Simultaneous heat transfer during the flow and
onset of solidification.
METHODS TO DESIGN AN
OPTIMIZED GATE
• Experimentation through trial and error methods for a
given casting geometry.
• Mathematical model.
BASIC COMPONENTS
OF A GATING
SYSTEM.
• Pouring
Basin.
• Sprue.
• Sprue well.
• Runner.
• Ingate.
POURING BASIN.
It is the funnel-shaped opening, made at the top of the mold. The
main purpose of the pouring basin is to direct the flow of molten
metal from ladle to the sprue.
. SPRUE WELL.
It is located at the base of the sprue. It arrests the free fall of
molten metal through the sprue and turns it by a right angle
towards the runner and also acts as a reservoir for the runners
and gates as they fill.
SPRUE.
• Connects the pouring basin
to the runner or ingate.
• Generally tapered
downward to avoid
aspiration of air.
• The round sprue has a
minimal surface area
exposed to cooling and
offers the lowest resistance
to the flow of metal.
• The square or rectangular
sprue minimizes the air
aspiration and turbulence
RUNNER
In case of large casting, the
fluidity length of the molten
metal is less than the
maximum distance required
to be travelled by the
molten metal along the flow
path. So it is necessary to
provide the multiple ingates
to reduce the maximum flow
distance needed to be
travelled by the molten
metal.
GATE (INGATES)
It is a small passage which connects the runner to the mould
cavity. The cross section is square, rectangular and trapezoidal.
GUIDELINES TO DESIGN A GATING
SYSTEM
• The size of the sprue fixes the flow rate.
• The sprue should be located at certain distance from the
gates so as to minimize velocity of molten metal at ingates.
• Rectangular cross-section sprue is better than circular one
with the same cross-sectional area, since critical velocity
for turbulence is much less for circular sections.
• In addition, vortex formation tendency in a sprue with
circular cross section is higher.
• Sprue should be tapered by approximately 5% minimum to
avoid aspiration of the air and free fall of the metal.
• Ingates should be located in thick regions.
• Multiple gating is frequently desirable.
• Rectangular cross section of runners and ingates are generally
preferred in sand castings.
BERNOULLI’s
THEOREM
APPLICATION
Bernoulli’s theorem
2
𝑝 𝑣
h+ + =¿
constant
𝜌𝑔 2𝑔
2 2
𝑝1 𝑣 1 𝑝2 𝑣 2
h 1+ + =h2 + + +𝑓
𝜌 𝑔 2𝑔 𝜌 𝑔 2𝑔
Assuming f=0 and system
remain at atmospheric
pressure
No turbulence and friction.
2 2
𝑣1 𝑣2
h 1+ =h2 +
2𝑔 2𝑔
CONTINUTY
EQUATION
Q AV
1 1 A2V2
Q=Volumetric flow rate
A= Cross section area
V = Velocity
Applying Bernoulli’s Equation at 2
and 3.
2 2
𝑣2 𝑝2 𝑣3 𝑝3
h2 + + =h 3+ +
2𝑔 𝜌 𝑔 2𝑔 𝜌 𝑔
( 𝑣 23 − 𝑣 22 ¿ 𝜌 𝑔
𝑝 2= +𝑝 3 − h2 𝜌 𝑔
2𝑔
𝐴2 𝑣 2 = 𝐴3 𝑣 3
𝑝 2 =𝑝 3 − h2 𝜌 𝑔
2 2
𝑣2 𝑝2 𝑣3 𝑝3
h 2+ + =h3 + + (1)
2𝑔 𝜌 𝑔 2𝑔 𝜌 𝑔
h 3=0
𝑝2 =𝑝 3=𝑎𝑡𝑚 .𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
2 2
𝑣2 𝑣3
h2 + =
2𝑔 2 𝑔
𝐴 2 𝑣 2= 𝐴 3 𝑣 3
𝑣 2 = 𝑅 𝑣3
𝑏𝑢𝑡
𝑣 3 = √ 2 𝑔 h𝑡
Then put the values in the
equation (1)
2
h3 𝑣2
1= 2
+ 2
𝑣3 𝑣3
2𝑔
2 h2
𝑅 =1 −
h𝑡
2 h𝑡 − h2 h𝑐
𝑅 = =
h𝑡 h𝑡
𝑅=
h𝑐
h𝑡√
𝐴3
But R=
𝐴2
Thus,
A3 h
c
A2 ht
GATING RATIO
Areas of Choke : Runner
: Gate(s)
The base of the Sprue and Choke are the same.
The ratios between the cross-sectional Area can be
grouped into either Pressurized or Unpressurized.
Pressurized: A system where the gate and runner cross-
sectional areas are either equal or less than the choke
cross-sectional area. Ac
Unpressurized: The key distinction is that the Runner
must have a cross sectional area greater than the Choke,
and it would appear that the Gate would equal or be
larger than the Runner.
Ac= Choke area, mm2
Wc = product mass, kg
W= Casting mass (poured metal mass), Kg
W= 1.3 Wc
t = Pouring time, s
d = Mass density of the molten metal, Kg / mm3
g = acceleration due to gravity, mm /s2
H = Effective metal head ( sprue height), mm
C = Efficiency factor which is a function of the
gating system used
t = K2 sec
K2 is a constant whose value is given by 1.30 for top
gating, 1.80 for bottom gating & 1.5 for parting
The effective sprue height H , of the mould depends on the casting dimensions
and type of the gating used. It can be calculated using the following relations.
Top gate, H= h Bottom gate H = h - and parting gating H = h -
Pressurized gating Ac: Ar: Ai = 1:
2: 1 (Al & Mg alloys)
Unpressurized gating Ac: Ar: Ai = 1: 2:
2 ( Fe & Cu)
Working Example
V1 = 30*([400-160]/2)*pi[400+160]/2
V2 = (pi/4)[(240^2) –(160^2)]*160
V3 = ????
V4 = ???
Total Volume = ??V1+ ??V2 +??V3 + ??V4
Correction:
160 mm not 161 mm
Eng. Mohamed H. El-Moayed 1/1/2023 21
THANK YOU
ANY
QUESTIO
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