Design of Riser

Design of Riser
Riser Design
Solidification of casting
Chvorinov rule
Functions of riser
Types of riser
Methods for riser design
Keywords: Solidification shrinkage, Cooling characteristics,

Freezing ratio, modulus, NRL method
Solidification of Casting
• Duringsolidification metal experience

shrinkage which results in void
formation.
• This can be avoided by feeding hot spot
during solidification.
• Riser are used to feed casting during
solidification.
What Are Risers?
• Risers are added reservoirs designed to
feed liquid metal to the solidifying
casting as a means for compensating for
solidification shrinkage.
• Riser must solidify after casting.
• Riser should be located so that
directional solidification occurs from
the extremities of mold cavity back
toward the riser.
• Thickest part of casting – last to
freeze, Riser should feed directly to
these regions.
Why Risers?
• The shrinkage occurs in three stages,

1. When temperature of liquid metal drops
from Pouring to Freezing temperature
2. When the metal changes from
liquid to solid state, and
3. When the temperature of
solid phase drops from
freezing to room temperature
• The shrinkage for stage 3 is

compensated by providing shrinkage
allowance on pattern, while the shrinkage
during stages 1 and 2 are compensated
by providing risers.
Riser Location & Types
Solidification Time For Casting
• Solidification of casting occurs by loosing heat from the

surfaces and amount of heat is given by volume of
casting .
• Cooling characteristics of a casting is the ratio of
surface area to volume.
• Higher the value of cooling characteristics faster is the
cooling of casting.
Chvorinov rule state that solidification time is inversely
proportional to cooling characteristics.
Solidification time
Where
Ts = Solidification time
V = Volume of casting
SA = Surface area K = mould constant
Chvorinov's Rule
n
V 
TST  C m  
 A
where TST = total solidification
time;
V = volume of the casting;
A = surface area of
casting;
n = exponent usually taken
to have a value = 2; and
Cm is mold constant
8
Mold Constant in Chvorinov's Rule
Cm or K depends on mold material, thermal properties

of casting metal, and pouring temperature relative to
melting point
Value of Cm or K for a given casting operation can be
based on experimental data from previous operations
carried out using same mold material, metal, and pouring
temperature, even though the shape of the part may be
quite different
9
Heat Transfer: Chvorinovs Rule
Solidification time is proportional to volume of casting and its

surface area
2
 volume 
time  C  
 surfacearea 
C: constant reflects mold metal properties

Example
Q: Three pieces being cast have the same volume but different
shapes.
One is a sphere, one a cube and the other a cylinder(Height =
Diameter).
Which piece will solidify the fastest and which the slowest.
Solidification time a 1/(surface area)2
Assume volume to be unity
Sphere V = (4/3) pr3, r=(3/4p)1/3 and A = 4pr2 = 4p(3/4p)2/3 = 4.84
Cube V = a3, a=1, A= 6a2 = 6
Cylinder V = pr2h = 2pr3, r=(1/2p)1/3, A = 2pr2 + 2prh = 6pr2 = 6p(1/2p)2/3
= 5.54
Thus respective solidification times are
Tsphere = 0.043 C
Tcube = 0.028 C
Tcylinder = 0.033 C
C is a constant
• A cylindrical riser must be designed for a sand-
casting mold. The casting itself is a steel
rectangular plate with dimensions 7.5 cm x12.5 cm
x 2.0 cm. Previous observations have indicated
that the solidification time for this casting is 1.6
min. The cylinder for the riser will have a
diameter-to-height ratio as 1.0. Determine the
dimensions of the riser so that its solidification
time is 2.0 min.
• V/A ratio= (7.5x12.5x2) / 2(7.5x12.5+12.5x2
+7.5x2)
• = 187.5 / 267.5 = 0.7
Methods of Riser Design
• Following are the methods for riser design:
1. Caine’s Method
2. Modulus Method
3. NRL Method
Caine’s Method
• Caine’s +
equation
Where
X = Freezing ratio
Y = Riser volume / Casting volume
A, b and c = Constant
Freezing ratio
Constant For Caine’s Method
• Values of constants are given in table:

Example:1
NRL Method
• NRL stand for Naval research Laboratory.
• NRL method is essentially a simplification of Caine’s method.
• In this method shape factor is used in place of freezing ratio.
Shape factor
NRL Method
• Ratio of riser volume to casting volume can be obtained from
graph shown below.
• After obtaining riser volume riser diameter and height can be
obtained.
• Use H/D = 1 for Side riser and H/D =0.5 for Top riser
Example:2 Design a suitable
riser for the given casting
Solution: Neglecting branch first calculate shape factor
Shape factor = (Length + Width)/ Thickness
= (25+ 12.5)/5 =7.5
Volume of casting VC = 25 x 12.5 x 5
= 1562.5 cm3
Volume of riser VR = 0.575 x VC
= 0.575 x 1562.5
= 898.43 cm3
Volume of riser VR = 2.5 x 2.5 x 10
= 1562.5 cm3
This is a plate feeding bar with a thickness ratio of 0.5,
hence from figure 4.30 (PN Rao), we get parasitic volume
as 30 %
Hence riser volume = 0.30 x 62.5 + 898.43 = 917.2 cm3
Riser diameter D = 10.53 cm
Modulus Method
Modulus is the inverse of the cooling characteristic ( surface
area/ Volume) and is defined as
Modulus = Volume / Surface area
In steel casting riser with height to diameter ratio of 1 is generally
used.
Volume of cylindrical riser =
Surface area =
For sound casting modulus of riser should be greater than the

modulus of casting by a factor of 1.2. Therefore Mr = 1.2 Mc
On simplification D = 6 Mc
Considering contraction of metal
MODULI OF SIMPLE SHAPES

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Design of Riser

Keywords: Solidification shrinkage, Cooling characteristics,

• Duringsolidification metal experience

• The shrinkage occurs in three stages,

• The shrinkage for stage 3 is

• Solidification of casting occurs by loosing heat from the

Cm or K depends on mold material, thermal properties

Solidification time is proportional to volume of casting and its

C: constant reflects mold metal properties

• Following are the methods for riser design:

• Values of constants are given in table:

Volume of cylindrical riser =

For sound casting modulus of riser should be greater than the

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