Gating System

Fluid Flow
• Gating system design strongly depends on knowledge of fluid flow
• Sprue-Runner, Pouring basin, risers

Problems
• Premature cooling
• Turbulence
• Gas entrapment
• Frothing and impurity
• Reaction with mold producing gas
Fluidity of molten metal
• Fluidity = capability of the molten metal
to fill the mold cavities

Factors influencing fluidity

• Viscosity: Increasing viscosity and sensitivity
to temperature reduces fluidity
• Surface tension: High surface tension
reduces fluidity
• Inclusions:Insoluble particles reduce fluidity
• Solidification Pattern

• Fluidity α 1/(Freezing Range)

• Pure metals act with good fluidity (lower

freezing range)
• Casting parameters also affect fluidity
1. Mold design
2. Mold material (heat mold for good fluidity)
3. Degree of superheat helps better fluidity
4. Rate of pouring
5. Heat transfer which affects viscosity
 Measuring fluidity
• A test for measuring
fluidity using a spiral
mold
• The fluidity index of
the material is the
length of the solidified
metal in the spiral
passage
• The greater the length
of the solidified metal
greater is the fluidity
Two Principles of fluid flow

• Bernoulli’s theorem
• Law of mass continuity
• Will help in design of gating system

Bernoulli’s Theorem
• h + (P/ρg) + (v2/2g) = constant
• h: elevation from reference plane h1 + (P1/rg) + (v12/2g) = h2 +
• P: pressure at the elevation (P2/rg) + (v22/2g) + f
• ρ : density of fluid
• v: velocity of the fluid
• g: gravitational constant
• F : frinction
Laws of Continuity
• For incompressible liquids the rate of flow is constant
Q = A1V1 = A2V2
Q: rate of flow m3/s
A: cross sectional area
V: velocity if fluid flow

Factors Affecting
• Permeability
• Gas loss
 Design of Sprues

A1 h2

A2 h1
• As the liquid flows down the cross section of the
fluid decreases. So the taper is provided in the
sprue
• Liquid loses contact if sprue is straight-causes
‘Aspiration’
 P1 = P3, Level 1 is
hc
constant
h2 ht V1 = 0, assume no
frictional loss
ght = (v3)2 /2

v3  2 gh t
Time to fill mold
Tf = V/ AgV3
Ag : cross sectional area
V: volume of mold cavity
Flow Characteristics
• Important characteristics in fluid flow is Turbulence as
opposed to Laminar Flow
• Reynolds number
Re = vDr/η
v: velocity
D: diameter
r: density
η: viscosity
• Re is usually between 2000 and 20000
For Re above 20000
• ‘dross’ formations occur caused by air and gases
• Scum on top can get mixed with alloys

Elimination techniques
• Avoid sudden changes in fluid flow
• Avoid sudden changes in cross section
• ‘dross’ can be reduced by filters ( ceramic, mica)
• Also with proper pouring basin and gating system
 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
 Various features of a sand mold
Vent Pouring basin(cup)
Open riser

Core
Sand

Flask

Blind Riser
Cope Sand

Parting
line

choke
Drag Mold
Cavity Sand
Runner

gate
Here we need to use:
• – Reynold’s number
• • values below 20,000 are OK in casting
• – Bernoulli’s equation
• – Continuity