By:

Engr. Muhammad Ishtiaq

1st Lecture

FOUNDRY
Afoundryis a factory that pours molten metal
into molds, producing cast metal objects.
Metals are cast into shapes by melting them
into a liquid, pouring the metal in a mold,
and removing the mold material or casting
after the metal has solidified as it cools.

DIFFERENT SECTIONS IN FOUNDRY:

1)
2)
3)
4)
5)
6)
7)
8)

Pattern making
Sand mixing & preparation
Mould and core making
Mould assembly & handling
Melting
Pouring
Shaking out (the process that de-sands thecasting)
Fettling & finishing
(the removal of feeders and excess material from a casting)

9)
10)

Heat treatment
Inspection & testing

GATING SYSTEM

The series of funnels, pipes and channels used to guide

liquid metal from the ladle into the mould cavity is known
as the gating system or the running system

OPEN MOLD VS. CLOSED MOLD

cope not required

liquid metal poured
directly into the mould
cavity
skill of foundrymen
important

(Partially Sectioned)
filling the mould
represents the greatest
of challenges
design of running
system is crucial

COMPONENTS OF GATING SYSTEM

The main components of a gating system
are:
Pouring basin or bush.
Sprue or downspure.
Sprue Well
Runner
Ingate
Ladle
Slag trap or filter

COMPONENTS OF GATING SYSTEM

Pouring basin :This is otherwise called as
bush or cup. It is circular or rectangular in
shape. It collects the molten metal which is
poured from the ladle.
Sprue :It is circular in cross section. It leads
the molten metal from the pouring basin to
the sprue well.
Sprue Well :It changes the direction of flow
of the molten metal to right angle and
passes it to the runner.

COMPONENTS OF GATING
SYSTEM
Runner :The runner takes the molten metal from
sprue to the casting.
In-gate: This is the final stage where the molten
metal moves from the runner to the mold cavity.
The positioning of the in-gate is important to get rapid and
uniform metal fill into the die. The in-gate should be
positioned to feed into the heavier sections of the
component and also minimize the length of the longest
run path.

Slag trap :It filters the slag when the molten

metal moves from the runner and ingate. It is
also placed in the runner.

GATING SYSTEM
The four main points which enables a proper
gating system are:
Clean molten metal
(The mold cavity must be filled with a clean metal so that it
prevents the entry of slag and inclusions into the mold cavity, which
in turn minimizes the surface instability)

Smooth filling of the casting cavity

(it helps to reduce the bulk turbulence)

Uniform filling of the casting cavity

(it means that the casting fill is in a controlled manner)

Complete filling of the casting cavity

(the metal thin with minimum resistance at the end sections)

REQUIREMENTS OF GATING SYSTEM

Fast pouring to: Minimize temperature loss
during mould filling.
Minimize metallurgical fade.
Minimize oxidation.
Clean pouring to: Avoid slag (dross)
generation during pouring.
Screen out slag from first iron poured into
mould.
Economic Design: Maximize casting yield.

CLASSES OF GATING SYSTEM

Top pouring system

Side pouring system
Bottom pouring system

Top Pouring System

Faster pouring rate
less fluidity
requirement
Severe splashing
and mould erosion
Oxidation of liquid
metal resulted
Favourable
temperature
gradient

Bottom Pouring
System
Filling against
gravity
quiet entry to
mould cavity
Elimination of
splashing and mould
erosion
less oxide formation
Unfavourable
temperature
gradient

(a poor bottom-gated filling system because

of direct entry of high velocity liquid into the

mould cavity)

(an improved version of the previous

bottom-gated filling system)

Longer sprue

Shorter sprue

CONTROLLING FACTORS

Type of gating system(top / bottom pouring,

pressurised / unpressurised system)
Pouring temperature (fluidity of metal)
Type of pouring equipment(ladle / pouring cup
/ pouring basin)
Rate of pouring
Size and type of runner and sprue
Size, number and location of in-gates

GATE
Basic purpose of the gate is to limit the flow of the
melt, but it must allow that melt flow and fill the
cavity easily.
Considering the fluidity of the material, gate should
be made near the center of gravity of molding or
the line to make flow uniform and melted material
even, then make the gate thick but still
considering melted plastic material, becouse thin
part will cooled easily and faster.
the gate type is very various depend on part
shape, mold layout, mold system, etc, here some
explanation about design those gate type:

TYPES OF GATES
Direct (sprue) gate
Commonly used for single-cavity molds,
where the sprue feeds material directly into the
cavity rapidly with minimum pressure drop.
Disadvantage:
The gate mark left on the part surface after
the runner (or sprue) is trimmed off.
Typically, the part shrinkage near the sprue gate will
be low; shrinkage in the sprue gate will be high.
This results in high tensile stresses near the gate.

TYPES OF GATES
Tab Gate
Typically employed for flat and thin parts.
A tab gate is used extensively for molding PC,
acrylic, SAN, and ABS types of materials.

TYPES OF GATES
Edge (standard) gate
An edge gate is located on the parting line of
the mold and typically fills the part from the
side, top, or bottom.

TYPES OF GATES
An overlap gate
is similar to an edge gate, except the gate
overlaps the wall or surfaces. This type of
gate is typically used to eliminate jetting.

TYPES OF GATES
A fan gate

a wide edge gate with variable thickness.

It permits rapid filling of large parts or fragile mold
sections through a large entry area.
It is used to create a uniform flow front into wide parts,
where warpage and dimensional stability are main
concerns.
The gate should taper in both width and thickness, to
maintain a constant cross sectional area. This will
ensure that:
The melt velocity will be constant
The entire width is being used for the flow
The pressure is the same across the entire width.

TYPES OF GATES
Disk ( Diaphragm) gate
often used for gating cylindrical or round
parts that have an open inside diameter.
Used when concentricity is an important
dimensional requirement and the presence
of a weld line is objectionable.
This gate is essentially a flash gate around
the inside edge of the part. Since the
diaphragm is fed from a concentric sprue
(or stub-runner drop), uniform flow to all
parts of the gate is easy to maintain.

TYPES OF GATES
Ring Gate
A ring gate is also used for
cylindrical or round parts, but it is
not always recommended.
With a ring gate, the material
flows freely around the core
before it moves down as a uniform
tube-like extrusion to fill the
mold.

TYPES OF GATES
Spoke ( Spider) Gate
This kind of gate is also called a fourpoint gate or cross gate. It is used
for tube-shaped parts and offers
easy de-gating and material savings.
Disadvantages are the possibility of
weld lines and the fact that perfect
roundness is unlikely.

TYPES OF GATES
Film ( flash) gate
A film gate is similar to a ring gate, but
it is used for straight edges. It consists
of a straight runner and a gate land
across either the entire length or
width of the cavity or a portion of the
cavity. It is used for acrylic parts, and
generally for flat designs of large areas
where warpage must be kept to a
minimum.

TYPES OF RUNNER
(DEPENDING UPON TEMPERATURE)
1. Standard runner system
2. Cold runner system
3. Hot runner system
standard runner system are directly
machined into the mold plates (plates 2 or
plate 3) but we can also make in special
plate that called runner plate, this plate
usually use in 3 plate mold type and attached
in plate three(cavity plate)
at this picture below shown that runner
directly machined in plate three