Analysis and Optimization of Gating System for Commutator End Bracket

Abstract

A well-designed runner and gating system is very important to produce good quality die castings by providing a homogenous mould filling pattern. Flow analysis of the component is done in order to visibly analyse the cavity filling process. In this study, a Commutator End (CE) bracket, a cold chamber die casted product was chosen. Initially when the component was casted numerous defects such as Cold shuts, Misrun, Shrinkage porosity and Gas porosity were found. This in turn led to rejection of number of components. In order to improve the quality of the castings produced, the gating system was changed from the existing flat gate to modified spoon fed gate. The component was designed using Pro-Engineer and flow analysis was carried out using Rotork Flow 3D Software. The process parameters like metal temperature, fill velocity and filling time are considered for optimizing the process. Quality assessment for the die casting parts was made by microstructure analysis.

Analysis of Mechanical Properties of Casted Aluminium Alloy for Automotive Safety Application

“…The material used in this project was the aluminium alloy AlSi 9 Cu 3 with a density of 2.7 g/cm 3 . Aluminium alloys are used to produce components with high strength and high dynamic load ability, which are predestined for use in areas such as aerospace and automotive industries [5][6][7][8][9]. The material used in the present study had a composition of 90% of aluminium, 3% copper and 7% silicon.…”

Investigating the causes and remedies for porosity defects in the casting process: A review

“…Cold shut and misrun are two additional defects that can occur during casting. Remedies for cold shut and misrun defects include optimizing gating and riser design, adjusting the casting temperature and speed, and using proper mold coatings (22).…”

Runner Optimization Of Hpdc Coolant Pump Housing Component Through Flow Analysis

“…The runner system consists of a pathway channel from the sprue bush-spreader area until the gating system before the cavity. The gating system is the mediator between the runner and cavity and provides regulation to the metal flow before entering into the cavity, making it the most restrictive part of the system [1]. Overflows are simple extra pockets provided around the opposite end of the runner system to account for the material shrinkage.…”

“…Overflows are simple extra pockets provided around the opposite end of the runner system to account for the material shrinkage. The runner layout must also be designed keeping in mind to abstain from including straight edges or lines as much as possible as it increases the turbulency of the flow [1]. With the implementation of larger components in the die casting process, the number of errors due to air entrapment is also a key factor to be tackled.…”