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Design and Analysis of Gating and Risering System For Casting of Ball Valves
Design and Analysis of Gating and Risering System For Casting of Ball Valves
Design and Analysis of Gating and Risering System For Casting of Ball Valves
I. I NTRODUCTION
Fig. 1: 3D CAD model of ball valve
ASTING is a one of the economical manufacturing
C processes used in foundries, There are two important
stages in casting, first is filling process and second is solidifi- for improving product also mold design to get the desired
cation process, In filling process gating system is designed to casting qualities. Conventional sand casting is not a precision
guide liquid metal filling. Riser system is used to compensate process and requires machining and surface finishing process
shrinkage caused by casting solidification. Systemic Casting after casting. However, advanced high technology sand casting
process design is important for production quality and yield. process enables this method to produce higher precision cast
Poor design results in many different defects such as porosity, products with better surface finishing that reduces the cost of
incomplete filling, crack and hot tear. machining and surface finishing processes. This will enhance
Hence how to improve the casting quality and reduce defects the capability of sand casting to produce almost exact shape
becomes important. Casting quality is mainly dependent on the products and improve its qualities. [8]
systematic gating and risering design, which is mainly relied
on workers experience.Computer assisted casting solidification A. Modelling Process
process helps the foundry industries to optimize the design pa- Generally the simulation software has three main parts:
rameters, better understand the mould filling and temperature Pre-processing: the program reads the CAD geometry and
history of the solidifying castings hence to identify the defects generates the mesh, Main processing: adding of boundary con-
with the aid of obtained time-temperature contours. [3] ditions and material data, filling and temperature calculations,
Pro-CAST is a three dimensional solidification package Post processing: presentation, evaluation.
developed to perform numerical simulation of molten metal Casting simulation package reqiures three dimensional CAD
flow and solidification phenomena in various casting pro- model for the simulation purpose. CAD model should be
cesses, It is very helpful for foundry applications to visualize designed with gating and risering system. Computer simulation
and predict the casting results so as to provide guidelines based on the design procedures described above have been
P. G. Panchal is with Mechanical Engineering Dept., Shankersinh
implemented with one case study. consider main body of ball
Vaghela Bapu Institute of Technology, Gandhinagar, Gujarat, India Email: valve for the present study. creo 1.0 is used to develope the 3D
pranav.panchal@bapugkv.ac.in CAD model of the part. 3D Model of ball valve with gating
S. J. Joshi is with Department of Mechanical Engineering, Institute
and risering system is shown in figure 1 and mold of ball valve
of Technology, Nirma University, Ahmedabad, Gujarat, India Email: is shown in figure 2.
s.j.joshi@nirmauni.ac.in
II. METHODOLOGY
N. D. Ghetiya is with Department of Mechanical Engineering, Insti-
tute of Technology, Nirma University, Ahmedabad, Gujarat, India Email: The purpose of this paper is to simulate the mechanism
nilesh.ghetiya@nirmauni.ac.in of the solidification of sand castings for the ball valve, and
NIRMA UNIVERISTY JOURNAL OF ENGINEERING AND TECHNOLOGY VOL. 4, N0. 1, JAN-JUN 2015 2
Option 1 Option 2
No.of Risers 10 6
Riser size (mm) 152.5*89 178*127
Runner size (mm) 50*50 50*50
Ingate size (mm) 40*40 60*60
Sprue size (mm) 65 65
Fraction solid
Fig. 5: Temperature Distribution The shrinkage cavity and slack can be predicted with the
computer simulations of the filling and solidification processes.
Shrinkage porosity of the riser but it is acceptable at this
model 1, the simulated results indicated that the shrinkage position. As metal solidify it is going to change phase from
defect and shrinkage porosity remains in the casting. It also liquid to solid and going to shrink so the compensating
shows step by step variation of temperature distribution and liquid metal available from riser due to this reason riser must
Fraction of solids. The original casting is shown in Figure 4 solidify last. Shrinkage factor for every metal are different
with gating and risering system design. it depends on its chemical composition and cooling process.
Temperature Distribution 1.95% defects shown in Fig.7
Above Contour Plots shows that at some of the location
The phase changes from liquid state to solid states of casting, temperature gradient becomes too high and this is
gradually with the decrease of temperature, in which a lot the potential cause of porosity and shrinkage therefore at that
of physical and surrounding parameters play an important location, we have to change geometry of casting if application
role for the casting quality. Temperature distribution of ball does not allow to change geometry of casting then we have
valve body with respect to time is shown in Fig.5. The to use either chiller or change the casting process. Riser
temperature distribution at time step 0 shows that whole shell design can change to achieve better casting yield compare to
is at same temperature i.e. pouring temperature. Temperature existing design.
distributions a different time steps are shown in various color.
From graphical result, change in phase from liquid to solid Option 2(Modified)
can easily find out. The input parameters for casting simulation are given in the
Table 1 and the size of gating and risering system has given
in the Table 2. In model 2, the size of riser height is changed
to 178 mm and riser diameter is changed to 127 mm. Here
NIRMA UNIVERISTY JOURNAL OF ENGINEERING AND TECHNOLOGY VOL. 4, N0. 1, JAN-JUN 2015 4
V. C ONCLUSIONS
2 side risers are removed. Total number of risers becomes 6.
Modified casting shown in Fig.8. The Fig.9 to Fig.11 shows The developments in the production of castings, computer
the simulated results obtained by using FEM based casting simulation can be a useful tool for rapid process development.
simulation of model 2. In Fig.9 temperature distribution at
step 0, 270.490,600 are shown. Step-270 indicates uneven
solidification. At time step 0, fraction solid is zero and as
time step passes latent heat is removing form metal and phase
change occurs. After step 220 the model is completely solid
as shown in Fig.10. As shown in Fig.10, step-220 indicates
high temperature is generating in flange area so shrinkage
porosity will occur in these flanges. 1.05 % defects indicate
in fig.4.11. As shown in figure metal will change phase from
liquid to solid and it will shrink and compensating liquid metal
available from riser. This model gives least porosity and it is
acceptable. Fig. 11: Shrinkage porosity of option 2
Option 1 Option 2
A. Comparison of Results No.of Risers 10 6
Solidification plots shows that at some of the location of Riser size (mm) 152.5*89 178*127
Runner size (mm) 50*50 50*50
casting, temperature gradient becomes too high. This is the Ingate size (mm) 40*40 60*60
potential cause of porosity and shrinkage at that location. Sprue size (mm) 65 65
As a remedial step change in geometry of casting design Porosity % 1.95 1.05
can achieve better casting yield compare to present design. Yield % 58 66.1
Original model is compared with modified models. Table 3 TABLE III: Comparison of Results
shown the comparison of the both models. The table reveals
NIRMA UNIVERISTY JOURNAL OF ENGINEERING AND TECHNOLOGY VOL. 4, N0. 1, JAN-JUN 2015 5
Application of casting simulation software in foundries can be Prof N D Ghetiya is an Associate Professor in
able to optimize the size and the position of the risers to avoid the Mechanical Engineering, Institute of Technol-
ogy, Nirma University, Ahmedabad. He has received
shrinkage defect in the casting. his, post graduate degree from IIT, Bombay with
New design has the following improvements: manufacturing Engineering as specialization and is
pursuing Ph. D in the area friction stir welding. His
• The casting simulation software results are matching
present interests include manufacturing processes
experimental results. and their analysis.
• Modified design reduces shrinkages porosity defect.
• The casting yield is increased by 8 %.
• The modified casting is clearly a better proposition since
it increases productivity while at same time decreasing
production costs.
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