Calculation of riser, design of gating and simulation of mold

filling, simulation of riser and gating system.

Riser Design
The riser is a reservoir in the mold that serves as a source of liquid metal
for the casting to compensate for shrinkage during solidification. The
riser must be designed to freeze after the main casting in order to satisfy
its function

Riser Function As described earlier, a riser is used in a sand-casting mold

to feed liquid metal to the casting during freezing in order to compensate
for solidification shrinkage.
To function, the riser must remain molten until after the casting solidifies.
Chvorinov’s rule can be used to compute the size of a riser that will
satisfy this requirement. The following example illustrates the
calculation.

The riser represents waste metal that will be separated from the cast part
and re-melted to make subsequent castings. It is desirable for the volume
of metal in the riser to be a minimum.
Since the geometry of the riser is normally selected to maximize the V/A
ratio, this tends to reduce the riser volume as much as possible

Risers can be designed in different forms. The design shown in Figure

below is a side riser. It is attached to the side of the casting by means of a
small channel. A top riser is one that is connected to the top surface of the
casting. Risers can be open or blind. An open riser is exposed to the
outside at the top surface of the cope. This has the disadvantage of
allowing more heat to escape, promoting faster solidification. A blind
riser is entirely enclosed within the mold, as in Figure below.
 Optimum Riser Design
The role of the methods engineer in designing risers can be stated
simply as making sure that risers will provide the feed metal:

• · In the right amount

• · At the right place

• · At the right time

Also we must consider the following

2. The riser/casting junction should be designed to minimize riser

removal costs
2. The number and size of risers should be minimized to increase
mold yield and to reduce production costs

3. Riser placement must be chosen so as not to exaggerate potential

problems in a particular casting design (for example, tendencies
toward hot tearing or distortion)

Also and the most important rule is riser solidification time must be
longer than casting solidification time by Chvor I no v’s rul e

𝑽
𝑻 𝒓 = 𝑪𝒎( )𝟐
𝑨
𝑻𝒓 > 𝑻𝒄
𝑽 𝑽
) > ( )𝑪
𝑨
(
𝑹 𝑨

(V/A) Ratio also known as the modulus , Another ratio is important is

the (H/D) Ratio between 1:1-1:1.5
Riser Location
To determine the correct riser location, the methods engineer must make use of the concept of directional
solidification. If shrinkage cavities in the casting are to be avoided, solidification should proceed directionally
from those parts of the casting farthest from the riser, through the intermediate portions of the casting, and
finally into the riser itself, where the final solidification will occur. Shrinkage at each step of solidification is
thus fed by liquid feed metal being drawn out of the riser.

The ability to achieve such directional solidification will depend on:

• · The alloy and its mode of solidification

• · The mold medium

• · The casting design

Riser Shape
1.Cylindrecal

2.Spherical (Ideal) impossible by Manufacture (Hemi-Spherical

Actually)
 Gating system

• The term gating system refers to all passageways through which the molten metal passes to enter the mould
cavity.
• The gating system is composed of
Pouring basin
Sprue
Runner
Gates
Risers
Requirements needed in gating system to achieve a free casting defects:
1- The mould should be completely filled in the smallest time possible without having to rise metal
temperature.
2- The metal should flow smoothly into the mould.
3- The unwanted material – slag – should not be allowed to enter the mould cavity.
4- The metal entry into the mould cavity should be controlled.
5- A proper thermal gradient be maintained.
6- Metal flow should be maintained to avoid erosion.
7- Be ensure that enough molten metal reaches the mould cavity.
8- The gating system should be economical and easy to implement and remove after casting solidification.
9- The casting yield should be maximized.
Factors controlling the functioning of gating system:
1- Type of pouring equipment, such as ladles, pouring basin etc.
2- Temperature/ Fluidity of molten metal.
3- Rate of liquid metal pouring.
4- Type and size of sprue.
5- Type and size of runner.
6- Size, number and location of gates connecting runner and casting.
 G
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Position of mould during pouring and solidification.
Pouring Basin

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• A pouring basin makes it easier for the ladle operator to direct the flow of metal from crucible to sprue.
• Helps maintaining the required rate of liquid metal flow.
• Reduces turbulence at the sprue entrance.
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• Helps separating dross, slag etc., from metal before it enters the sprue.

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 Sprue
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1- A sprue feeds metal to runner which in turn reaches the casting through gates.
2- A sprue is tapered with its bigger end at top to receive the liquid metal. The smaller end is connected to
runner.
Gates t
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• A gate is a channel which connects the mould cavity.

• A small gate is used for a casting which solidifies slowly and vice versa.

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• A gate should not sand pieces thus may be carried with the molten metal in the mould cavity.

Types
• Top gate
• Bottom gate
• Parting line side gate
 Bottom Gate:

• A bottom gate is made in the drag portion.

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• In a bottom gate the liquid metal fills rapidly the bottom portion of the mould cavity and rises up the mould walls.
• As comparison to top gate, bottom gate involves little turbulence and sand erosion.
• Bottom gate produces good casting surfaces.
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• If freezing takes place at the bottom, it could choke off the metal flow before the mould is full.
• Creates an unfavourable temperature gradien and makes it difficult to achieve directional solidification.

Design of gating system

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

Estimation of optimum pouring time.
Calculation sprue choke area.
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 Selection of appropriate gating system.
 Selection of gating system and ingate location.
 Calculation of runner ingate size.

Formula –

1) Calculation of pouring time

2) Gray cast iron <450kg
3) Pouring time t=(1.4+T/14.59)W sec
4) Where,
K is fluidity factor which depends upon temperature and composition of molten metal.
K= fluidity of iron in inches /40
T= average thickness of the casting in mm.
W= mass of the casting in kg.

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