Optimization of Multi-Gate System in Casting Process Based on Experimental Study

Abstract

Abstract: This paper proposes a gating system design for casting process using an experimental study. The principle behind multi-gate system optimization is to eliminate defects such as compression gas inclusions, cold shorts and mixing etc. Industrial and research experience shows that the flow of molten metal in the gating system before entering the extraction cavity significantly influences the quality of the casting. In general, slow filling causes defects like cold shirt and mixing while fast filling causes inclusion of sand and causes defects like holes. A gating system consists of runners, sprue gates and filters. The position, number, size, and shape of these elements play an important role. A systematic methodology for gating design optimization considering filling rate maximization has been developed based on limiting constraints. These include pouring time, gating ratio, modulus of ingate, mold erosion, Reynolds number at ingate section and filling rate of molten metal. Molten metal kinematics viscosity similar to that of liquid water can be used to determine the fillings and flowrate of the molten metal in the mold cavity. Aluminum generally has the same kinematics as water. Thus the water flow can be studied by adding the necessary design improvements to the multi-gate system, from which it will be easier to detect defects and will be easier to detect defects and will greatly improve the overall casting quality