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Lect 9

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50 views21 pages

Lect 9

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e22mecu0009
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LECTURE 9

Gating Ratio
Gating ratio refers to the relation between area of the choke
to total area of runner to total area of Ingates. Mathematically, it
can be written as Ac: Ar:Ag .
The gating system completely controls the molten metal
flow. Gating systems can be classified as Pressurised system
and Unpressurised system.
Gating ratio depends on the nature of the molten metal.
• Pressurized system is used for reactive metals like magnesium
alloy etc. Unpressurised gating system is used for normal metals
such as brass, steel, aluminium alloy, etc.
• A Gating ratio such as 1:2:1 or 1:0.75:0.5 refers to pressured
system; whereas the gating ratio such as 1:2:2 or 1:3:3, 1:1:3,
refers to unpressurised gating system.
Streamlining the gating system
Streamlining includes;
1. Removing sharp corners or junction by giving a
generous radius.
2. Tapering the sprue.
3. Providing radius at sprue entrance and exit.
Advantages of Streamlining

1. Metal turbulence is reduced.

2. Air aspiration is avoided.

3. Mould erosion and dross are minimized.

4. Sound and clean castings are obtained.


Objectives for a Good Gating System Design

1. To fill the mould cavity without breaking the flow of


liquid metal and without using very high pouring
temperatures.
2. To fill the mould with the minimum possible time
without causing turbulence in flow
3. To avoid erosion of mould cavity.
4. To minimize turbulence and dross/slag formation.
5. To prevent aspiration of air or mould gases in the
liquid metal stream.
6. To obtain favourable temperature gradient so as to
promote directional solidification.
Gating System Design

This includes the design/ calculations of ;


1 Pouring time.
2 Choke area.
3 Sprue.
4 Gating ratios.
5 Slag trap system.
Pouring Time

• Pouring rate is defined as the time taken for filling the mould
cavity by a known quantity of metal. Pouring time is used as an
index to determine the pouring rate.
• When molten metal is being poured into the mould at a very fast
rate, mould erosion, rough surface, excessive shrinkage may
take place.
• When the pouring rate is very low, the complete filling of the
mould is not assured and may result in excessive drop in the
molten metal temperature. This results in casting defects such as
cold shut, misrun etc.
• In order to avoid this, it is necessary to arrive at the correct rate
of pouring of metal into the mould cavity.
Pouring time

The pouring time depends on:

1. Casting materials,

2. Casting complexity,

3. Casting size, and

4. Section thickness.
Design Calculations for Pouring Time

1- Gray cast iron: mass less than 450 kg:


 T 
t = K 1.41+  W
 14.59 
fluidity of iron ininches
K=
40
K: fluidity factor.
T: average section thickness, mm
W: mass of the casting, kg
2- Gray cast iron: mass greater than 450 kg:
 T 3
t = K1.236 +  W
16.65 
Pouring Time
3 Steel casting:

t = (2.4335− 0.3953logW ) W
4 Ductile iron:
t = K1 . W
K1 = 2.08 for thinner sections.
K1 = 2.67 for sections of 10 to 25 mm thick.
K1 = 2.97 for heavier sections.
Pouring Time
5- Copper alloy castings:

t = K2 3 W
The factor K2 is ;
Top gating 1.30
Bottom gating 1.8
Brass 1.9
Tin bronze 2.8
Choke Area
It is the main control area which meters the metal flow
into the mould cavity so that the mould is completely filled
within the calculated pouring time.
W
A=
d t C 2gH
A: choke area, mm2 W: casting mass, kg
t: pouring time, s H: sprue height, mm
d: mass density of the molten metal, kg/mm3
C: efficiency of the used gating system.
Numerical

In a gating design, the gating ratio is 1:2:3. It is used to produce a


mass of 30 kg. Density of material is 2600 kg/m3 and the mould
filling time is 11.2 s. Height of the liquid metal above the sprue is
250 mm and the efficiency of gating system is 0.98. Determine the
diameter of choke, runner and gate.
Most commonly used Gating Ratios

Gating Ratio for Pressurized Gating Systems

1) Choke Area: Runner Area: Sprue Area = 1:1.3:1.1 - for Grey C.I
2) 1: 2 : 1 for Aluminium
3) 1: 2 : 1.5 for Steel

Gating Ratio for Unpressurized Gating Systems

1) Choke Area: Runner Area: Sprue Area = 1:4 : 4 - for Grey C.I
2) 1: 3 : 3 for Aluminium
3) 1: 3: 3 for Steel
Design a gating system for a casting made up of C.I whose dimensions
are 500 x 250 x 50 mm
Density of solid C.I = 7.86 gm/cc
Fluidity length = 22 inches, Height of sprue = 100 mm
Density of liquid C.I = 6.9 gm/cc
Efficiency factor = 0.8
Take casting yield as 80%
Volume of casting = 500 x 250 x 50 = 6250 cc

Mass of casting = 6250 x 7.86 = 49125 gm = 49.125 kg

Taking casting yield as 80%


Weight of metal poured = 49.125/0.8 = 61.41 kg

Pouring time = 20.846 s = 21 s

61.41
Choke Area = = 450 mm2
6.9 𝑥 10−6 𝑥 21𝑥0.8 2 𝑥 9810𝑥100

Diameter of the choke = 23.93 mm = 24 mm

Gating ratio for Grey CI = 1:4:4 (unpressurized system)


Runner Area = 4 x choke area
1) Calculate the optimum pouring time for a casting whose mass is 50 kg and
having an average section thickness of 20 mm. The casting material is Grey
C.I. Take the fluidity of material as 25 inches.
Given:

K: fluidity factor.
T: average section thickness, mm W: mass of
the casting, kg

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