Effects of Improved Gating System by Using Standard Gating Ratio
Effects of Improved Gating System by Using Standard Gating Ratio
Effects of Improved Gating System by Using Standard Gating Ratio
ABSTRACT: One of the key elements to make a metal casting of The gating system is made up of the following parts: - a)
high quality is the design of a good gating system. The gating Pouring basin b) Sprue c) Runner bar d) In gates e) Riser
system refers to those channels through which the metal flows
from the ladle to the mold cavity. The use of a good gating system
is even more important if a casting is produced by a gravity
process. If poor gating techniques are used, invariably, lower
casting quality is achieved, because of damage on the molten
metal received during the flow through the gating system. It could
be even worse, if the molten material is a sensitive metal for
receiving damage during the filling, because of dross and slag
formation. The purpose of this study is to identify the problem
associated with gating system for the manufacturing of ginning
dead weight which is used for their machineries at Jadhao Steel
Fig. 1. Gating system 3D
Alloys, Amravati . The typical casting defects were identified at
M/s Jadhao Steel Alloys, Amravati in which the shrinkage defect
,blow holes, pin holes, gas holes, sand inclusion and misrun The design of gating system is important and the main
defects etc. are prominent. The total percentage of defect is requisites of gating system are: The gating should be so
around 25-30 % of the total casting produced. It means total % of designed that it avoids the mould or core erosion by reducing
rejection is around 25-30% which is very high and not acceptable. metal velocity within the cavity and avoiding direct
After careful investigation of the casting process, it was found impingement on mould walls or cores. The flow of metal to the
that all the above defects can be considerably reduced by using a mould cavity should occur with as minimum as possible
proper gating system. Hence optimization of gating system is turbulence, because if turbulence is excessive, the aspiration of
considered as a main topic of investigation. According to deep
mould gases will occur which will oxidize the mould metal.
study and analysis of existing gating system used by industry, it
was found that old gating ratio was incorrect and after gating
system calculations it was found that the total of weight of gating The flow of molten metal must be laminar so as to
system is very high that has to reduce considerably. After careful reduce the casting defects like shrinkage, porosity, blow holes,
observation and analysis of existing gating system used by gas holes, misrun, sand inclusion etc.
industry, it was decided to make necessary changes in the design
and dimension of gating system. By using proposed gating system IMPORTANCE OF GATING SYSTEM
the experiment has been carried out at Jadhao Steel Alloys,
Amravati. The result found after experimentation are very sound
and productive. By using standard gating ratio as per ISO, it was The design of gating system is as important as rise
found that the total percentage of productivity improved from ring of a steel casting. It is well known that improper gating
42% to 74% by reducing total weight of gating system from 4.68 practice can result in defects like , ceroxide, inclusions, cold
kg to 2.39 kg with reducing total percentage of rejection from shuts, misruns, hot tears, local shrinkages, and gas cavities in a
25% - 30% to 7.5% - 10%, With % of yield increases from 86% steel casting. A gating system should be pre-designed and
to 92%, with keeping flow laminar through all sections of gating incorporated in method drawing as is the case of rise ring and
system which is most essential to reduce casting defects. not left to the discretion of the molder.
CONSTITUENTS OF GATING SYSTEM
Keywords – Gating Ratio, Gating System, Jadhav Steel Alloys,
A gating system for steel castings can be broadly
Casting Defects, Productivity.
divided into: - The entry section – consisting of the pouring
basin, sprue and sprue base. The distribution section
INTRODUCTION consists of the runners and in gates.
a) To supply liquid metal free of entrapped gases, slag and study and analysis of existing Gating System used by
eroded sand. industry.
b) To establish a hydraulic pressure head, this will force the
metal through the rest of the gating system and into the STUDY AND ANALYSIS OF EXISTING GATING
casting. SYSTEM
Following table shows the inspection report for Fig. 2. Ginning Weight
ginning weight at quality desk. DIMESIONAL DRAWING OF GINING WEIGHT
Blow
Job shrink holes Sand % of
Misrun Total
Qty age & gas inclusion rejection
holes
20 3 2 1 6 30%
20 1 1 1 2 5 25%
20 1 1 1 1 4 20%
20 2 2 1 - 5 25%
20 2 1 - 2 5 25%
20 1 3 1 - 5 25%
Average percentage of rejection is around 25% to 30%
Existing Gating
Existing Gating
System
Sr. No. Part Area2
Dimensions (mm )
(mm) GATING RATIO AND CALCULATION FOR PROPOSED
GATING SYSTEM
D1= 20
1 Sprue 491
D2= 25
According to changes in the dimensions of existing
L= 60, H= 65,
2 Runner
T= 23
920 gating system, the followings calculations are made in order
to maintain standard gating ratio. With these calculations for
L=30, H=15, proposed gating system gating ratio will changes to
3 In gates w=40, L=30, 1050
H=5,W=40
Cross sectional area of sprue = 491mm2
Cross sectional area of runner = 1000 mm2 produced flow pattern is laminar through all typical section of
Cross sectional area of in gates = 505 mm2 existing and proposed gating system with typical variation in
Therefore 491: 1000: 505 = 1:2.03: 1.02 mean velocity because of changes in the dimension of existing
gating system. In order to reduce various casting defects by
TABLE IV: Gating area for existing & proposed gating system using existing gating system this flow pattern analysis plays an
important role during manufacturing of Ginning Dead Weight.
Existing Proposed Existing Proposed
Gating Gating Gating Gating EXPERIMENTAL RESULTS, ANALYSIS AND
Sr.
Part System System Area Area
No
Dimension Dimensions
DISCUSSION
2 2
s (mm) (mm) (mm ) (mm )
D1= 20 D1= 20, By using proposed gating system the experiments has
1 Sprue 491 491
, D2= 25 D2= 25 been carried out at Jadhao Steel Alloys, Amravati. The result
L= 60, H= L= 60, H=
2 Runner 65, 65, 920 1000 found after experimentation are very sound and productive. By
T= 23 T= 25 using standard gating ratio as per ISO, it was found that the total
L=30 weight of gating system reduced from 4.68 kg to 2.39 kg with
H=15,w=4 L=20, reducing total percentage of rejection from 25% - 30% to 7.5% -
0, H=12,w=30 10%, With % of yield increases from 86% to 92%, with
3 In gates 1050 505
L=30, ,L=5,
H=5, W=20,H=5 productivity increases from 42% to 74%, with keeping flow
W=40 laminar through all sections of gating system which is most
Gating ratio becomes (1:1.87:2.13)(1:2.03:1.03) essential to reduce casting defects.
Hence It was found that proposed gating ratio, becomes INSPECTION REPORT
(1:2.03:1.02) is matched with std. gating ratio i.e. 1:2:1 as per
researchers research in foundry technology. TABLE VI: Inspection Report by using proposed gating system
REFERENCES
Appendix
Experimentation Images