Multi-Gate Systems in Casting Process: Comparative Study of Liquid Metal and Water Flow

Renukananda, K. H.; Ravi, B.

doi:10.1080/10426914.2015.1037911

Cited by 17 publications

(15 citation statements)

References 11 publications

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“…It also provides filling against the gravity, allowing the achievement of non-turbulent filling, in sharp contrast to top pouring. It is one of the aspects of filling technology strongly recommended by Campbell and others (Ref 19,[22][23][24][25]. All modeling trials have been made using the steel grade GS-52 according to DIN 1681, with the pouring temperature set at…”

Section: Experimental Methodsmentioning

confidence: 99%

Optimized Gating System for Steel Castings

Dojka

Jezierski

Campbell

2018

J. of Materi Eng and Perform

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Computer modeling using a commercially available software package was used to explore the optimization of filling systems based on the relatively new concepts of avoiding entrainment of air bubbles and oxides by avoiding surface turbulence. The test casting was based on a pattern for a traditional top poured test bar, whose cross section was a tri-lobed clover-like shape. The study illustrates clearly that the detailed design of the filling system has a major influence on the conditions for defect generation during filling. Traditional steel casting systems using the widely popular assembly of preformed refractory tubes were found to behave poorly. Systems were demonstrated which were capable of delivering highly controlled filling behavior. The latest systems to be developed employed (1) a naturally pressurized filling system and (2) the use of filters placed flush on the top of the runner to act as bubble diverters, together with (3) terminal spin traps. These novel filling systems demonstrated excellent performance in simulation, in agreement with practical experience of the capability (of the trident gate in particular) to produce, for the first time in the history of casting, defect-free castings on a routine basis.

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Section: Experimental Methodsmentioning

confidence: 99%

Optimized Gating System for Steel Castings

Dojka

Jezierski

Campbell

2018

J. of Materi Eng and Perform

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“…This is illustrated by the effect of the extra insulation applied in set-up 3, as shown in Figure 5a. Although uneven flow in a multi-cavity system has been previously reported in literature, 22 the effects of misalignment and asymmetry of filling have not been reported previously.…”

Section: Resultsmentioning

confidence: 81%

Effects of Process Related Variations on Fillablity Simulation of Thin-Walled IN718 Structures

et al. 2017

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Simulation tools have improved significantly and are now capable of accurately predicting mould filling behavior. The quality of prediction is highly dependent on material properties and set-up of boundary conditions for the simulation. In this work material properties were measured and casting conditions were analyzed to accurately replicate the casting process in simulation. The sensitivity of the predictions to minor process variations commonly found in foundries was evaluated by comparing simulation and cast samples. The observed discrepancies between simulation and cast samples were evaluated and discussed in terms of their dependency on process variations. It was concluded that the simulation set-up was capable of reasonable predictions and could replicate the asymmetry of the filling however did not accurately predict the absolute value of the unfilled area. It was discovered that asymmetric flow due to variations in the orientation of the casting mould during filling could have greater influence on the predictions than the actual variation in fill time. The quality of simulation is dependent on equipment and techniques used in the foundry as well as the metallurgical model to simulate the process.

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“…Fig.3 shows the casting components with the experimental set up of a runner, liquid basin, sprue, well runners, gates and slag traps. Factors like the shape and the size of the feeder and feeder neck, location of the feeder, insulating sleeves and covers, fins and chills have been taken into account in designing the feeder system to avoid shrinkage defects at different regions [20]. At the same time, a perfect gating system can ensure smooth, complete and uniform filling with less time enabling detection and elimination of many defects…”

Section: A Significance Of Feeding System In Casting Processmentioning

confidence: 99%

“…The main purpose of introducing the gating system is to connect a number of casting cavities for achieving higher productivity [20]. On the other hand, in the horizontal feeding system, the symmetrical arrangement of gating was found more suitable for a thick wall casting, exhibiting uniform temperature distribution, flow and air entrainment.…”

Section: B Based On Component Orientation Of Gating Systemmentioning

confidence: 99%

“…They have also developed an empirical relation based on the experimental data obtained for the percentage of flow rate through the four gates. The results have led the selection of appropriate material for correct gating system from the simulation model various condition as reported by researchers [20]. The same research group have referred to an earlier case of the study of numerical simulation of flow of water and aluminum alloy LM6 through a multi-gate gating system which has been pictorially represented [31].…”

Section: Based On Type Of Gating Systemmentioning

confidence: 99%

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Effectiveness of Feeding System for Enhanced Product Quality in Sand Casting Industries

2019

IJRTE

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This review article deals with the importance of process parameters and the recent developments in modern tool technology in the success of smart productivity for casting process of all types. Various influencing factors such as design, location and the number of gating on feeding mechanism were discussed vis-a-vis casting defects. The review revealed reduction in the defects such as air bubbles, blow holes, shrinkage defects and mechanical properties of the casting parts through selection of an optimum feeding design. Variations in fillet radius and thickness on the feeding system were found to be the factors affecting the location of the hot spot. Accordingly, the mobility of the hot spot was controlled by geometrical modifications in the feeding system. In addition, the formation of pinholes and solidification defects could be reduced through a proper arrangement of the feeding system. The rapid growth in implementing simulation techniques in the casting process can assist the enhancement of yield with minimum production cost. This article provides a data base relating to the merits and demerits of various factors and material systems with their industrial applications for enabling further research in the casting process

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Multi-Gate Systems in Casting Process: Comparative Study of Liquid Metal and Water Flow

Cited by 17 publications

References 11 publications

Optimized Gating System for Steel Castings

Optimized Gating System for Steel Castings

Effects of Process Related Variations on Fillablity Simulation of Thin-Walled IN718 Structures

Effectiveness of Feeding System for Enhanced Product Quality in Sand Casting Industries

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