Professional Documents
Culture Documents
1.
2.
3.
4.
5.
6.
7.
Pouring Basin
Sprue
Sprue base well
Runner
Runner extension
Ingate
Riser
1.Pouring Basin
2.SPRUE
The molten metal when moving from top of the cope to the
parting plane, gains in velocity and as a consequence requires
a smaller area of cross section for the same amount of metal
to flow.(constant flow rate)
If straight sprue is used, the metal flow would not be full at
the bottom, but some low pressure area would be created
around the metal in the sprue.
Since the sand mould is permeable, atmospheric air would
be breathed into this low pressure area which would be
carried to the mould cavity.
To eliminate this problem of air aspiration the sprue is
tapered to gradually reduce the cross section as it moves
away from the top of the cope as shown.
3. Sprue
base well
This is a reservoir for metal at the bottom of
the sprue to reduce the momentum of the
molten metal.
The molten metal gains velocity as it moves
down the sprue, some of which is lost in the
sprue base well by which the mould erosion is
reduced.
This molten metal then changes direction
and flows into the runners in a more uniform
way.
4.Runner
Runner
Ingate
Runner full
5.Runner
extension
6.Gates
Also called as Ingates
Openings through which the molten metal
enters the mould cavity.
These are 4 types:
1.Top gate
2.Bottom
gate
3.Parting
gate
4.Step gate
Top gate
Disadvantage:
Likely to cause mould erosion
Causes turbulence and hence prone to form
dross
Suitable only for simple casting shapes
Bottom
gate
Will not cause any mould erosion
Used for very deep moulds
Disadvantages
Very unfavorable
temperature
gradient
Special sprue or core
is required
Parting gate
Top gate
Bottom gate
Step gate
Used for heavy and large castings
The molten metal enters mould cavity
through a number of ingates which are
arranged in vertical steps
7.Ris
er
Metals & alloys shrink during solidification
Material
Medium carbon steel
High carbon steel
Aluminium
Aluminium alloy(Si 13%)
Shrinkage(%)
2.5 to 3.5
4
6.6
3.5%
Types of
risers
1.Top risers:
Open to the atmosphere.
Most conventional and convenient to make.
Loses heat to atmosphere by radiation &
convection.
To reduce heat loss, insulation is provided on
the top by plaster of paris and asbestos sheet.
Position where it can be placed is limited.
2.Blind risers:
Completely concealed inside the mould cavity
itself.
Lose heat slowly and hence more effective.
More conveniently located than an open riser.
3.Internal riser:
Surrounded on all sides by the casing such
that heat from the casting keeps the metal in
the riser hot for a longer time.
Used for castings which are cylindrically
shaped or have a hollow cylindrical portions.
Best riser
Chill
Chills are large heat sinks, so heat is quickly absorbed
by the chill from the larger mass making the cooling
rate equal to that of the thin sections.
Thus chill does not permit the formation of a
shrinkage cavity.
Metallic
chills
are
used
to
provide
progressive solidification or to avoid the
shrinkage cavities.
Hard spot will form at the contact area of chill,
needs
further machining
Whenever, it is not possible to provide riser for
a part of the casting which is heavy, a chill is
placed close to it as shown in figure.
CASTING YIELD
New material
Melting losses
Fettling losses
Metal melted
Metal cast
Actual
casting
Scrap metal
Scrap
castings
Runners &
Risers
Casting Description
Simple and massive shape
Casting Yield
0.85 to 0. .95
Steels(simple shape)
0.75 to 0.85
0.55 to 0.65
Steels(Small pieces)
0.35 to 0.45
0.65 to 0.75
0.45 to 0.55
Aluminum
0.25 to 0.45