Computer Aided Riser Design
Computer Aided Riser Design
Introduction
The use of computer-aided design and computer-aided linked together to form a casting CAD system. In this paper,
manufacturing in industry increases the efficiency of the product modeling capability, automatic design of a pattern,
design and manufacturing processes. The resulting high pro- and automatic design of risers will be described. The remain-
ductivity makes the use of CAD/CAM an attractive and prof- ing topics will be covered in Part 2.
itable goal for industry. Our work is unique in that it generates a mold in a complete
An ideal CAD system for the casting process would three-dimensional geometric model by uniting the three-
minimize the time delay between the design stage and the dimensional models of a pattern, risers, and gating systems, so
manufacturing stage of a product. In the CAD/CAM area, that a finite element analysis pre-processor, NC processor, etc.
there exist already the technologies which minimize the time can be linked directly.
delay between those two stages. To apply the existing The casting material to be handled in the system is primarily
technologies to the casting process, the three-dimensional ductile cast iron but the same method may be applied to gray
model of a casting mold is the essential part. To produce a iron.
three-dimensional model of a casting mold, it is necessary to
prepare the proper pattern, the riser, and the gating system.
These are designed based on the geometry of the final product Related Work
to a large extent. This fact indicates the possibility of creating The use of computer-aided design as a tool for the casting
a CAD system which generates the three-dimensional model of industry has been addressed by Graham [1] and Welbourn [2].
a casting mold once the geometry of the final product is Graham puts emphasis on the usage of existing CAD systems
specified. for the casting industry and Welbourn describes the
According to this point of view, the objective of this work is capabilities that the casting CAD system should have. Work
the development of a CAD system for casting processes by by Berry and Pehlke[3] has been directed at modeling a casting
which the complete three-dimensional model of a casting mold for thermal analysis; however, direct pattern and mold design
can be automatically generated. To develop this system, the has not been discussed. Heine and Uicker [4] have developed
following problems should be solved: the CAST METALS PROGRAM in which riser design and
• Product modeling capability freezing order calculations are performed. Gerhardt [5] also
• Automatic design of a pattern developed a program to compute the dimensions of a gating
• Automatic design of risers and a risering system by a systematic/logical approach. The
• Automatic design of gating systems Dynarad Corporation developed software for calculating
• Completion of a mold risers and gating systems, NO VAC AST [6], by using some ax-
In our system, each of these segments is developed and ioms and certain well-established empirical information. None
of the works above generates a mold in a complete three-
Contributed by the Production Engineering Division for publication in the
dimensional geometric model. Smith and Lee [7] developed a
JOURNAL OF ENGINEERING FOR INDUSTRY. Manuscript received May 1989. procedure that generates the proper patterns in complete
Product Modeling
Since the design of a mold is heavily dependent on the shape o
H i_ |2J
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N2 1
of a final product, there must be a way to provide the 1
geometric model of the final product which will act as an input L !
to the casting mold design system. To this end, the modeling
capability of a three-dimensional object was implemented by
incorporating the routines of' a constructive solid geometric
modeling system. The modeling capability of this system is
similar to that of commercially available constructive solid (a) (b)
geometric modeling systems [8, 9]. Hence, the Boolean opera- Fig. 1 The modification of a pattern based on shrinkage allowance
tions, such as union, subtraction, and intersection, can be per-
formed on the primitives. The primitives supported in this
product modeling system are box, cylinder, cone, prism,
sphere, and torus. As can be inferred from the supported
primitives, a product bounded by sculptured surfaces cannot
be handled in the system.
d i r e c t i o n of withdrawl
A
reference face
draft angle
O
O
Semi—convergence Semi—convergence
angle = o a ngl e = — 1 0°
Fig. A Draft operation on the pattern
( b )
plementation, the orientation of the parting plane has been Fig. 5 Draft operation on a cylindrical or a conical surface. Draft angles
of +10 degrees were provided in (a) and (b).
fixed to be the X-Y plane and thus only the location input is
required. Also, a stepped parting plane is not supported in the
current implementation. Once the parting plane is defined, the angle of a new surface is calculated as follows. If the
pattern is cut into two bodies as shown in Fig. 3. As in Fig. 3, original conical surface is "convex" as in Fig. 5(a), the
the bodies are separated for easy draft operation even though new semi-convergence angle becomes the original semi-
they will be glued together after the draft operation. convergence angle plus the draft angle. In the "con-
The principles used in the implementation of the draft cave" case, as in Fig. 5(b), the new semi-convergence
operation are described in the following steps. angle would be the original semi-convergence angle
• For each face parallel to the direction of withdrawal, minus the draft angle. Once the new parameters are
the user interactively assigns the reference face and the determined as discussed above, the new conical surface
draft angle shown in Fig. 4. In our system, the sign of is defined.
the draft angle is positive when the volume of the pat- By applying the draft operation as described above, the pat-
tern as a result of the draft operation increases. tern will be created with the proper draft. In the current im-
• The surface type of the face to be tilted is identified. plementation, the surface type of the face to be tilted is limited
For a planar face, the system searches one point on the to planar, cylindrical, and conical.
common edge between the reference face and the face
to be rotated and determines the rotational axis direc- Automatic Design of Risers
tion by taking the cross product between outer normal In this system, Karsay's applied risering method [10] has
vectors of the faces. Then the system computes the been employed and implemented. His method is based on a
rotational transformation matrix by means of the draft modulus which is the casting volume divided by its cooling
angle, the rotational axis, and the point on the rota- surface area, the metallurgical quality of the iron, and the
tional axis, and thus defines a new surface by applying mold rigidity. The family of applied risering methods is shown
the transformation matrix to the original surface. For a in Fig. 6[10], All the methods for riser design introduced in
cylindrical or a conical surface, the face is treated as a Fig. 6 were implemented in the system as discussed in the
conical face because a cylindrical face can be con- following sections.
sidered as a special case of a conical face for which the
semi-convergence angle is zero. Note that the semi- Selection of Risering Method. The first step to be per-
convergence angle is defined to be positive when the formed in designing a riser is to select the proper risering
axis direction of the cone points toward the apex. The method. The following explanation refers to Fig. 6. First, the
procedure for drafting a conical face is described as average modulus of a pattern is calculated and the proper
follows with reference to Fig. 5. First, the system iden- risering method based on the modulus is recommended by the
tifies the axis direction of the conical surface. If the system. The modulus of a pattern can be easily calculated
axis has a reverse direction with respect to the outer because the volume and the surface area of the pattern were
normal vector of the reference face, the axis direction already computed when it was modeled. Then, the proper
of the conical surface is reversed and thus the sign of risering method in consideration of the mold rigidity is
the semi-convergence angle is reversed too. The arrows selected interactively by the user as recommended by the
in Fig. 5 represent the axis direction and the outer nor- system even though the user can select a different risering
mal vector of the reference face after the adjustment method.
described above. Next, the base point and the base In this paper, our work is focused on the riser design based
radius of a new conical surface are obtained from the on pressure control risering which is the most popular in prac-
original conical surface. Finally, the semi-convergence tice. Even though theriser design based on the directly applied
-0.9
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-0.7 o°"
Weak Mold Strong Mold 1 1
-0.6
-0.5 sM
1 1
1.0—1-0.4 6 •^
Modulus(cm) Modulus(cm) r,n u
-0.3 _,
1 1
-0.2
1 /*
> 0.4 < 0.4 <2.0 > 2.0 -ni"
0.2-03- 0.4-0.5 0.6 -0.7 J 0.8-0.9 - I.O-U-, -1.2- Min.
1 ,i _,l . it ll
"1
0 1.0 2.0 3.0 Mem
Fig. 7 Relationship of geometric modulus to transfer modulus
I
"i r
2 3 4 5 6 7
,X> I -/ Modulus
Fig. 10 Relationship of modulus to shrinkage
Topmost point of riser
Type I Type 2
(contact in cope) (contact in drag.)
Effective teed metal ( shaded volume)
Topmost point of casting
H
Next, it calculates the volume of feed metal required by
to
the casting from the percent feed metal as in Fig. 10
and the casting volume.
• Finally, the system compares the effective feed metal
volume with the volume of feed metal required.
a=Mnx3 a = Mn x 4 If the effective feed metal volume is less than the volume of
Fig. 9 Shapes of riser neck the feed metal required, the system iteratively increases each
riser height.
Once the feed metal requirement is satisfied, the system up-
riser for each feeding unit is allowed in our system. Also, the dates the heights of the lower risers so that all risers have their
shapes of the riser neck shown in Fig. 9 are displayed and top in the same horizontal plane. Otherwise, in the initial stage
selected. Finally, from the moduli of the riser and the riser of the liquid contraction the lower positioned risers will be fed
neck for the feeding unit, the dimensions of the riser and its from the higher risers, and consequently this makes the lower
neck are calculated. Even for the case of multiple risers for risers useless and will create a very large shrinkage void in the
each feeding unit, the dimensions of the risers and their riser topmost riser.
necks are determined as for a single riser.
Modeling of Riser and Riser Neck. By using the Boolean
Adjustment of Riser Size. Since the riser has been con- operations between the primitives, the system models risers
structed based on the modulus, the riser dimensions must be and riser necks so that they have the dimensions as previously
adjusted so that the effective riser volume exceeds the volume determined. To model the risers represented in Fig. 8, the
of initial liquid feed metal required by the casting. primitives used for type 1 are cone and torus, for type 2 are
Figure 10 [5,10,12] illustrates the percent feed metal re- cone and sphere, and for type 3 are cylinder and sphere. Also,
quired by the casting based on the metallurgical quality and the system uses a box or cylinder to model the riser neck. For a
the average modulus of the casting. For programming pur- side riser, the system models the riser neck along the + X axis
poses, the curves were fitted and stored in the form of B-spline from the datum point, denoted by R l , and then models the
curve equations. riser at the position apart from the datum point by the neck
A schematic diagram to indicate the effective portion for a length along the + X axis, denoted by position A in Fig. 12.
side riser is shown in Fig. 11. The volume of effective feed The datum point is the origin of the reference coordinate
metal (EFM) for side risers is expressed[5] as system used by the embedded geometric modeling system. The
Case Study
edge E1
By using the system developed in this work, the pattern and
the risers for a gear blank casting have been designed. Figure
13(a) shows an initial menu and a final product constructed by
the system's modeling capability. The pattern with drafts and
adjusted dimensions based on the shrinkage allowance after
the elimination of the holes is shown in Fig. 13(6). Once the
final pattern is created, the pattern is split into three segments
and the feeding units from the analysis of the geometric and
transfer moduli of each segment are identified as shown in
Fig. 13(c). Then the segments to which the risers are attached
are identified, and the proper risers are designed considering
the feed metal requirement. After the layout of the risers, the
risers and the final pattern are united as illustrated in Fig.
Fig. 12 Layout ot a side riser
13(d).
SELECT MENU
MODELING
PATTERN DESIGN
RISER DESIGN
GATING DESIGN
MOULD ASSEMBLY
EXIT
ENDPICKI CANCEL J
QADAL
PLOT SCREEN SCREEN TOGGLE
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PATTERN DESIGN
HOLE ELIMINATE
SHRINKHGE
DRAFT
BLENDING
RETURN
BOOT Litrr
ENDPICK[CRNCCUI
CADAL
PLOT SCREEN SCREEN TOGGLE DISPLAY
PATTERN SECTION
zoom
ccroI I
MODULE BNRLYEIG
RISER LOCUTION
RISER CREATION
RETURN
•DOT LISt
ENDPlCKtCPNCELi
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SCO N D . HODULUS
fiopuuic
1 a.aa t.u
2 a. 1.0G
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0.5
CUMULATIVE VOLUME GHMEIM/10BI
MODEL INS
PATTERN DESIGN
RISER DESIGN
GATING DESIGN
MOULD ASSEMBLY
EXIT
Boo-r L i s t
C N P P I CK I C J 3 N C E L I
CABAL
PLOT SCREEN SCREEN TOGGLE
for the integration with computer aided engineering. Further- 5 Gerhardt, Jr., P. C , "Computer Applications in Gating and Risering
more, this system would become a very powerful tool for prac- System Design for Ductile Iron Castings," AFS Transactions, 1983, Des
Plaines, IL.
tical use if it could be linked with a knowledge-based expert 6 Dynarad Corporation, Novacast Demonstration Manual, available
system to collect the proper knowledge of human experts. through 14733 Catalina Street, San Leandro, CA, 1984.
7 Smith, C. T., and Lee, K., "Computer Aided Pattern Design for Casting
References Processes," AFS Transactions, 1986, Des Plaines, IL.
8 Requicha, A. A. G., "Representations for Rigid Solids: Theory, Methods,
1 Graham, H., "Computer Graphics for Casting Design," AFS Transac- and Systems," ACM Computing Surveys, Vol. 12, No. 4, Dec. 1980.
tions, 1981, Des Plaines, IL. 9 Cary, Chris, ROMULUS User's Reference Manual, Shape Data Ltd.,
2 Welbourn, D. B., "The Foundry and CAD/CAM: What is Required?" Apr. 1983.
AFS Transactions, 1983, Des Plaines, IL. 10 Karsay, S. I., Ductile Iron III Gating and Risering, QIT-Fer et Titane, Inc.
3 Berry, J. T., and Pehlke, R. D., "Computer-Aided Design For Castings," 11 Karsay, S. I., Encyclopaedia of Design Logic, QIT-Fer et Titane, Inc.
AFS Transactions, 1984, Des Plaines, IL. 12 Corlett, G. A., and Anderson, J. V., "Experiences with an Applied Riser-
4 Heine, R. W., and Uicker, J. J., "Risering by Computer Assisted ing Technique for the Production of Ductile Iron Castings," AFS Transactions,
Geometric Modeling," AFS Transactions, 1983, Des Plaines, IL. 1983, Des Plaines, IL.