ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

Vol-4, Issue-2, March 2016

DESIGN AND ANALYSIS OF GATING SYSTEM FOR SB-CNC TAIL

STOCK BASE CASTING
Rohith K R1, Rahul R2, Liroy Oppan3, Sheryl John 4, Amal Mohan 5, Renjith Venugopal 6, Susruthan A S7
Bessy Paul8, Saravanan B K9
1-7
(B-Tech student,Department of Mechanical Engineering, Nirmala College of Engineering, Thrissur,
Kerala, India)
8
(Deputy Engineer, Design section, Hindustan Machine Tool Ltd, Kalamassery, Kerala,India)
9
(Assistant Professor, Department of Mechanical Engineering, Nirmala College of Engineering, Thrissur,
Kerala, India)

ABSTRACT
The aim is to design and analyze the gating system for SB-CNC tail stock base casting with an intention of reducing
the cast defects. The assignment given by Hindustan Machine Tool Ltd, Kalamassery was to find a solution to
reduce the cast defects of SB-CNC tail stock base casting. On this we had conducted studies on the existing gating
system in search for the reasons of the cast defects. Based on the studies conducted with the help of product
planning and testing (ppt) department, we found out various factors affecting the cast quality. Some of the major
factors affecting the quality of the casting are blow holes, shrinkage and porosity. Significant amount of cast iron
are being used to fabricate components such as engine blocks, cylinder heads, lathe parts etc. Production of cast
iron castings is a complex process which involves many parameters that affect the quality of castings. In this
project, a new approach is attempted to produce sand grey cast iron casting of tail stock base by computer
simulation through experimental validation in a cast iron foundry. The gating system for SB-CNC tail stock base
casting is simulated by means of finite element simulation software (ANSYS)
Keywords: Gating system, optimization, CFD Analysis

1. INTRODUCTION
Casting is the process of producing metal/alloy
component parts of desired shapes by pouring the
molten metal/alloy into a prepared mould (of that
shape) and then allowing the metal/alloy to cool and
solidify. The solidified piece of metal/alloy is known
as casting [1].Incasting process, gating system plays an
important role to produce a high quality casting. A
poorly designed gating system results in casting
defects. A gating system controls mould filling
process. The main function of gating system is to
lead clean molten metal from ladle to the casting
cavity ensuring smooth, uniform and complete
filling. The flow of molten metal after being poured
is a transient phenomena accompanied by turbulence,
separation of the flow from the boundaries, dividing
and combined flow at the junction, simultaneous heat
transfer during the flow and onset of solidification.
Moreover melt properties like density, viscosity and
surface tension are continuously changing during the
flow. All this together makes the filling analysis quite
complex. An optimized gating design must satisfying
this entire requirement .All the assumptions were
made according to the rules given by P.N Rao [1].All
the formulas used in this project are taken from this
book.
V.Gopinath [2] employed a plate casting of dimension
240x150x25 mm with the combination of different
riser dimensions. Cylindrical riser of hemispherical
bottom with H/D=1 were taken for his analysis.
Solidification simulation was made with ANSYS
software, then the solidification time and optimal
riser diameters were compared with experimental
results.
Manjunath Swamy H M [3] optimized the gating and
risering system by using casting simulation software
ADSTEFAN. Through several simulation iterations,
it was concluded that defect free casting could be
obtained by modifying the initial gating ratio 2:2:1 to
2:1.76:1, by shifting the location of sprue from centre
to end and by providing the risers at location prone to
formation of shrinkage porosity which led to the
decrease in size of the shrinkage porosity about 97%.

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 ISSN No: 2309-4893
International Journal of Advanced Engineering and Global Technology
Vol-4, Issue-2, March 2016

M. Masoumi [4] experimented a direct observation

method in which he showed various flow patterns 2. DESIGN OF GATING SYSTEM
resulting from different gating designs and they were
recorded by a video camera and further analyzed by a Existing design
computerized system. The experimental results
indicated that the geometry and size of the gate and Table.1 Specifications of existing gating system
the ratio of the gating system could have a great
Parameters Equation used Result
influence on the pattern of mold filling
Pressurized
Gating system _
gating
Prof. Karl B. Rundman [5] has well explained about
Parting line
all sand casting process and other casting process, Gate type _
gating
melting of metals and alloys, fluid flow and gating
Runner type _ Rectangular
design solidification and processing of metal castings
accounts for defects in metal casting Sprue type _ Cylindrical

P.Prabhakara Rao [6] discussed a newly developed Mass of casting ρ= 114 kg

simulation tool and its application to a crusher
component that was prototyped via sand casting Pouring time t = k× [1.41+ ×√ 24 seconds
route. Results of casting trials showed a high level of
Mass of metal poured Casting yield= ×100 175 kg
confidence in the simulation tool known as Pro
CAST. Pro CAST is a three dimensional Pouring rate Pouring rate= 7.29 kg/sec
solidification and fluid flow package developed to
perform numerical simulation of molten metal flow Chock area Ac= 1416 mm2
√
and solidification phenomena in various casting
processes, primarily die casting (gravity, low Gating ratio As: Ar: Ag 1.1: 0.8: 1
pressure and high pressure die casting) and sand
casting. Sprue area As =1.1× Ag 1540 mm2
Sarath Paul [7] and Rathish R [7] designed cylindrical Runner area Ar=0.8× Ag 1200 mm2
riser of hemispherical bottom with h/d=1.3 is
considered for analysis. Solidification simulation is Ingate area Ac= Ag 1416 mm2
made with ANSYS software to compute
solidification time and optimal riser combinations to Sprue well Sprue well area= 3×As 4770 mm2
obtain defect free castings in the shop floor. The Diameter of riser _ 100 mm
experimental results revealed that the simulation
performed using ANSYS holds good to produce Height of riser _ 60 mm
defect free cast iron castings in the foundry.
[8] [8]
N.Jayakumar , Dr.S.Mohanamurugan , Optimizing design
[8]
Dr.R.Rajavel has well explained about design of
gating system for a pump casing and also about the Caine’s equation, X= …….[1]
generation of hot spots and its remedies

John Campbell [9] and Richard A [9] give an idea on X=

how to design a shrinkage free casting

V V Mane [10], Amit Sata [10] and M Y Khire [10], as Y=

well explained about cast defects and its
classifications. h=d = 140 mm (for side riser h=d)

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 ISSN No: 2309-4893
International Journal of Advanced Engineering and Global Technology
Vol-4, Issue-2, March 2016

Here Modulus of riser is 1.1 times that of modulus of Preprocessing

casting. Therefore, design is safe.
Optimized design
Table.2 Specifications of optimized gating system
The pre-processing process contains the following
commands to create a finite element model. They are
as follows:

Parameters Equation used Result  Defining Element and Options

Gating ratio As: Ar: Ag 1.1:1: 1  Defining Element Real constants
Runner area Ar=1× Ag 1416 mm2  Defining Material Properties
Runner type _ Trapezoidal
 Creating Model Geometries
 Defining Meshing controls
Diameter of _ 140 mm
riser
 Applying Boundary conditions.
Height of riser _ 140 mm
Model

3. COMPUTER SIMULATION The model is created in solid works and it is saved in

In the past, the optimal gating design was achieved .iges format and then it is imported to ANSYS for the
by trial and error method. Conventional method is solution to obtain.
time consuming and ineffective, can no longer
satisfies the needs of the foundry. This problem can
be addressed with the use of computer aided
design/engineering technique. Computer design and
casting simulation have gradually become popular in
recent years. With the help of the computer a number
of CAD/CAM commercial packages for the
simulations of the casting have been developed and
Implemented in the foundry. In this work, ANSYS
14.5 version software has been used to find the
optimum gating system forSB-CNC tail stock base
casting. Simulation process facilitates to visualize the
pressure and velocity distribution in various locations
of the casting.
Figure 1 Solid works model
Assumptions incorporated
It is difficult to incorporate all the environmental
condition existing in the foundry; hence the following
assumptions were made during simulation.

 The mould is filled instantaneously and

uniform temperature is assumed at all points
of the casting and mould, at that instant.
 Heat transfer by convection takes place to
the atmosphere from the outer surface of the
mould and top surface of riser and runner.
 The convective heat transfer within the
liquid metal is neglected for sand moulds.

Figure 2 Casting Model Imported into ANSYS

Software in .iges Format

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 ISSN No: 2309-4893
International Journal of Advanced Engineering and Global Technology
Vol-4, Issue-2, March 2016

Once the model has been subjected to various Velocity contour

boundary conditions ANSYS solves the set of
equations generated by Finite Element Model.
Computer simulation using ANSYS
The casting and mould assembly is modeled in the
Pre-processor stage of simulation. One half of the
casting and mould assembly is modeled as it is
symmetric.
Properties of grey cast iron

 Density= 7200 kg/m3

 Specificheat at constant pressure, cp= 0.46
kj/kg K
 Thermal conductivity, k= 46 w/mK Figure 5 Velocity contour of existing design
 Dynamic viscosity,µ= 5.857× kg/ms

Comparison between existing and optimized design

Pressure contour

Figure 6 Velocity contour of optimized design

Figure 3 Pressure contour of existing design 4. RESULT AND DISCUSSION

The analysis given by the ANSYS shows that the
negative pressure in optimized gating system is less
than that of existing gating system that the negative
pressure in optimized gating system is less than that
of existing.

5. CONCLUSION
A gating system was designed and optimized to
produce SB-CNC tail stock base casting using green
sand mould and a pressurized gating system with a
gating ratio of 1.1:1:1. Through this design, a low
turbulence uniform filling of mould cavities, lamina
flow through the runner and in gates to the mould
cavity and minimizes air entrapment in the mould
cavity was obtained. Thereby reduces the rejection
rate of the casting. From the CFD study, it is obtained
Figure 4 Pressure contour of optimized design

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 ISSN No: 2309-4893
International Journal of Advanced Engineering and Global Technology
Vol-4, Issue-2, March 2016

that the optimised gating system provides better
result.
“Gating system design in casting process is one of
the crucial factors to produce good quality of casting
product “
ACKNOWLEDGEMENT
This paper is the outcome of hard work with the help
and cooperation from many sources. We express our
gratitude and sincere thanks to college management,
professor K Vijayan Raja, head department of
mechanical engineering for the encouragement given
to us.
[8]“Design and analysis of gating system for pump
casing” N.Jayakumar et al. / International Journal of
Engineering and Technology (IJET)
[9] John Campbell and Richard A. Harding, The
Feeding of Castings, Training in Aluminum
Application Technologies, (TALAT) Lecture 3206,
1994.
[10] V V Mane, Amit Sata and M Y Khire, ―New
Approach to Casting Defects Classification and
Analysis Supported by Simulation‖.

REFERENCES
[1]P.N Rao,“Production Technology”, Edition1
(volume 3)

[2] V.Gopinath, N.Balanarasimman, “Effect of

Solidification Parameters on the Feeding Efficiency
of LM-6 Aluminum Alloy Casting”, IOSR Journal of
Mechanical and Civil Engineering (IOSR-JMCE)
ISSN: 2278-1684 Volume 4, Issue 2 (Nov. - Dec.
2012),
[3] Manjunath Swamy H.M, J.R.Nataraj, C.S.Prasad,
“Design Optimization of Gating System by Fluid
Flow and Solidification Simulation for Front Axle
Housing”, International Journal of Engineering
Research and Development,vol.4,PP.83-88,October
2012.

[4] M. Masoumi, H. Hu, “Effect of Gating Design on

Mold Filling”, Transactions of the American Foundry
Society, Vol-113,Pg 185-196,2005.

[5] Prof. Karl B. Rundman, METAL CASTING,

Reference Book for MY4130, 1986

[6] P.Prabhakara Rao, G.Chakraverthi,A.C.S.Kumar,

B.Balakrishna, “Application of Casting Simulation
for Sand Casting of a Crusher Plate”, International
Journal of Thermal Technologies, Vol.1.No.1
(Dec2011)

[7] “Simulation and experimental validation of

feeding efficiency FG 260 grey cast iron castings
“International Journal of Engineering Research and
General Science Volume 2, Issue 6, October-
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