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Unit 2 Notes

The sprue serves three key functions in casting: 1. It is the passage through which molten material is introduced into the mold. 2. It acts as a filter and heat sink to prevent impurities and provide continued feeding as the casting cools and shrinks. 3. Its design can be used to trap dross and sand to prevent them from entering the mold cavity. The design of gating and runners is also important for proper filling of the mold cavity. Equations can be used to calculate the filling time based on factors like mold area, gate area, material height, and gravity. Risers provide extra metal to compensate for shrinkage as the casting cools and solid

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34 views11 pages

Unit 2 Notes

The sprue serves three key functions in casting: 1. It is the passage through which molten material is introduced into the mold. 2. It acts as a filter and heat sink to prevent impurities and provide continued feeding as the casting cools and shrinks. 3. Its design can be used to trap dross and sand to prevent them from entering the mold cavity. The design of gating and runners is also important for proper filling of the mold cavity. Equations can be used to calculate the filling time based on factors like mold area, gate area, material height, and gravity. Risers provide extra metal to compensate for shrinkage as the casting cools and solid

Uploaded by

Selva
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© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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DESIGN OF SPRUE

Casting
In casting, a sprue is the passage through which a molten material is introduced into a mold, and the term also refers to the excess material which solidifies in the sprue passage. In sand casting, the sprue is formed by a dowel which is removed from the sand to make the hole into which the metal is poured.

Function
Sprues can serve as filters, heat sinks, and as feeders. Bronze in particular has a high shrinkage rate as it is cooling; a sprue can continue to provide molten metal to the casting, provided it is large enough to retain its heat and stay liquid, as metal in the main casting cools and shrinks. The design of the sprue and runner system can be also utilized to trap unwanted dross and sand from continuing into the main cavity; this may include adding porous material to the runners, or designing the sprue to eject the dross to the side of the sprue using cyclonic separation. ]Sprue

design

The design of gating and runner is also essential for casting. The design can be done by using vertical and bottom gating. For bottom gating

where: = Time for filling = Area of mold = Area of gate = Acceleration due to gravity = Total height = Height of mold cavity This equation may change if the height of gating is equal to height of casting material. Then the equation will be:

or, simplified,

where: = Time for filling = Area of mold = Area of gate = Acceleration due to gravity = Total height (Height of gating + height of mold cavity) = Height of mold cavity

DESIGN OF RISER
Riser is a source of extra metal which flows from riser to mold cavity to compensate for shrinkage which takes place in the casting when it starts solidifying. Without a riser heavier parts of the casting will have shrinkage defects, either on the surface or internally. Risers are known by different names as metal reservoir, feeders, or headers. Shrinkage in a mold, from the time of pouring to final casting, occurs in three stages. 1. during the liquid state 2. during the transformation from liquid to solid 3. during the solid state First type of shrinkage is being compensated by the feeders or the gating system. For the second type of shrinkage risers are required. Risers are normally placed at that portion of the casting which is last to freeze. A riser must stay in liquid state at least as long as the casting and must be able to feed the casting during this time. Functions of Risers Provide extra metal to compensate for the volumetric shrinkage Allow mold gases to escape Provide extra metal pressure on the solidifying mold to reproduce mold details more exact

Design Requirements of Risers Riser size: For a sound casting riser must be last to freeze. The ratio of (volume / surface 2 area) of the riser must be greater than that of the casting. However, when this condition does not meet the metal in the riser can be kept in liquid state by heating it externally or using exothermic materials in the risers. 2. Riser placement: the spacing of risers in the casting must be considered by effectively calculating the feeding distance of the risers. 3. Riser shape: cylindrical risers are recommended for most of the castings as spherical risers, although considers as best, are difficult to cast. To increase volume/surface area ratio the bottom of the riser can be shaped as hemisphere. 1.

DESIGN OF SPRUE

DESIGN OF GATING SYSTEM

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