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Subject Review

Design of Gating and Risering Systems in Sand Molds

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a-ramahi@yahoo.com :
( / / ): ( / / ):

.(Risering System) (Gating System)

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. :

Abstract
The success of a sand casting process depends mainly on the design of efficient
mold rigging systems; namely the Gating and Risering systems. However, it is observed
that the mold preparation, in most of local foundries in Palestine, depends totally on the
experience of the foundry man who does not pay much attention to the engineering
mold-design procedure. In fact, almost all of the foundry men in the local market have
gained their experience by trial and error which usually leads to higher production cost
and less production quality. This paper is a review paper. It reviews, in a simplified and
comprehensive way, the most important practical and scientific rules and procedures
related to Gating and Risering systems design. Detailed examples are also given to
explain the implementation of these rules and procedures. One main objective of the
paper is to contribute to the improvement of local-foundry efficiency. Therefore, the
 ( )“ ”

paper is written in Arabic to be available for the maximum number of researchers,

engineers, and other interested people. On the other hand, the paper presents a useful
summery of a list of the most important references related to the design of Gating and
Risering systems in sand casting. Further more, the material of the paper can support in
developing modern Computer Aided Mold Design Systems.
Key Words: Design of Sand Molds, Gating System, Risering System, Sand Castings.

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.

.
.
(1)
90%
(2)
. ( ) 85%

.
.

. (20-3)
.

( ) ( )
 .
.

(28-21)

.
:
. -
-
.
.
-
. ( )
-
.

Gating System : (
(Drag ) :
( ) (Cope )
. .

( ) ( )
( )“ ”

. (29)

: (1)
: (Pouring bush) .
.
. : (Sprue) .
. : (Well) .
. : (Runner) .
: (Gates) .
.

(30)
:(1)

( ) ( )
 : ,
: (31)
. .
. .
. .
. .
. .
Gating System Design : : ,

(15)
(The law of continuity) (Bernoulli’s Theorem)

.
Pouring Time Calculation : : , ,
) ( )
(
.

. (32, 17) Dietert

: Dietert

t q m (1 )
:
. :t
.( ) :m
1/2
( / ) :q

( ) ( )
( )“ ”

Dietert (1) q
40 15
. q = 1.35 q
(Q) (V)
: (39) (MFT)
MFT V/Q (2)
. (32) Dietert q :(1)

( )
5-6 7-14 15-40
1.94 2.0 2.3
1.15 1.2 1.35
1.22 1.4
1.77 2.0
1.93 2.2
1.3

)
: (15) ( 453.59) 1000 ( 14
T
t k 0 . 95 w (3)
0 . 853
:
. :t
( 0.45359 = 1) :w
k=1 . :k
.
( 25.4 = 1) ( ) :T

( ) ( )
(1)
: (33) (3)

t f w (4 )

. (2) f

. (33) (1/2 / ) f :(2)

f f

0.8 0.4-1.2

1.7 1.4-2.0 *

. (34) f = 1*

. (29) 45-15

(35)
Chvorinov .
a v( )
. (Casting Modulus: MC)
v
M C (5 )
a
(30)
( ) Campbell
MC (2)
.

( ) ( )
( )“ ”

(30)
:(2)

.
(30)
. 10%
Choke Area Calculations : ( ) : , ,

)
(Ag ) (As
(20)
: .

( ) ( )
 Pressurized Gating System : .

(32-31,20)
. (Ag)
(Ar) (Ag)
. (3) (As)
(32)
Ag : Ar : As :(3)

Ag : Ar : As

1 : 1.1 :1.2
1 :1.2 : 1.3
1 : 1 : 1.5
1 : 1.4 : 1.5

: (34, 32) ((6) ) Ag

VD
A (6 A )
t 2 gH

1.5(b)VC
A (6 B )
3 3
t 2g H (H b)

1 VD 1.5(b)VC
A (6C )
t 2g H H3 (H b) 3

( ) ( )
( )“ ”

.2 (Ag) (As) :A
. :
. :t
. 981 :g
.(3 ) : VD
.(3 ) : VC
. :H
. :b

. (4) .
(32)
. 0.5
. (32) :(4)

0.42
0.50
0.32
0.40

Non-pressurized Gating System : .

.
. (6) (As) . (32-31, 20) (As)

As : Ar : Ag .
. (5)

( ) ( )
 . As : Ar : Ag :(5)
As : Ar : Ag
1 : 1.1 : 1.8
1 : 1.2 : 3
1:2:3 -
1:3:6,1:2:4
1:2:4 -

(Ar) (As)
(Ag)
.
(Ag) . (34)

.
.

.
(4) . (3)
.

. (34) :(3)

( ) ( )
( )“ ”

. (34) :(4)

Pouring Cup (Bush) Dimensions : : , ,

: (32) (3 ) Vcup
5
m 4
V cup 400 (7 )
t

(5) .
:

(34)
:(5)

( ) ( )
 ( )w (5)
:
1
V cup
3
w (8 )
2 .5

Sprue Dimensions : : , ,
: (30) H,H1, As, A1 (6)

H
A1 As (9 )
H1

1
H 4

H d1 ds (10)
H1

(30)
:(6)

:
. : ds
. : d1
(H1 w) : H1
Sprue Base Dimensions : : , ,
(7)
(7) c
.

( ) ( )
( )“ ”

(14)
:(7)

: ,
(29)
(9) Heine

A =As (6) A .

(29)
:(8)

: (gating system) : ,

. (9)

( ) ( )
 . " " :(9)

:
(m) .

m Vtotal (11)
V . = Vtotal =
V . 3 0.00124 V 3/ 7000
(Vtotal)
(overall yield)
:
V
overall yield (12 )
V total
55% 35% overall yield
overall yield . (14)
2V Vtotal . %50
17.36 = m (8) . 3 0.00248 = Vtotal
.( 0.45359 = 1) 38.12 = m

( ) ( )
 ( )“ ”

(t) .
10.5 (2) 1.7 = f (4)
.
( ) .
Ag
. 0.5 = (4) (6A)
25 = H
2 1 = Ag (6A) . (10)
.2 1.5 = As 2 1 = Ar (3) .

25

:(10)

.2 0.5
.
(6) 3 750 V cup (5)
. 6.7 (H1 w ) H1
.
( , , )
:

( ) ( )
 ((7) ) 14 = ds -
. 14 7 ( ) -
.( ) 14 3.5 -
) 14 3.5 -
.(
.
. 20 = d1 (10)
. 18.3
.
. 14 28 (7)
.(9) ((11) )

(9) ( 11)

Risering System : (
(shrinks)
(steel) .

( ) ( )
 ( )“ ”

(Riser Feeder) .

.(Shrinkage Cavity)
(29)
: .
. %20 .
. .
: (40) Chvorinov
1
V 2
ts K (13 )
S
:
. :K
. :V
. :S
Riser Geometry : : ,

. (36)
.
(Tapered riser) . (Cylindrical riser)
.(7) (Heine's riser) Heine
Types of Risers : : ,
.
: (32)
(Open top Riser) .
(Blind side Riser) .
(Blind top Riser) .

( ) ( )
( ) () (Breaker core)

.
Risering System Design : : ,

:
. ( ) .
. .
. .
Riser Location : : , ,

.
(31)
( ) (feeding distance)
(12) . (Castings of uniform wall thickness)
. (bars) (plates)
T . (chills)
(37)
( 12.7) 0.5 T 8T 8T 3T
. ( 50.8) 2 T 3T
(Casting with sections of varying
thickness)
(late-solidifying sections) ( )
Chvorinov .
( )
. (Mc)

( ) ( )
( )“ ”

. (31) :(12)

Sizing of Risers : : , ,
(38)
Wlodawer
: . (16)Johns (18)
Heine
Wlodawer .
Chvorinov Wlodawer
. (M)
(MC) (MR)

( ) ( )
 .
(38, 31, 29)
: (MC) (MR)
MR =1.2MC ( 14 )
(Riser neck)
(MC) (MN)
:
MN = 1.1 MC ( 15 )

(MC) .
. [13]

(21)
:(13)

Wlodawer
:

( ) ( )
( )“ ”

VR 0.785D3 (16)
D H 6MR (17)
MR 1.2MC (18)

( ) VR
(14)
(Breaker-Core) .
50%-40% 10%
. (31)

(38)
:(14)

Wlodawer

( ) ( )
 (Plates)
. Wlodawer
Heine .

) . (18) ( )
. (Percentage of Volumetric Contraction) (
:
. (31) (S) :(6)

(S) (S)
4.9 2.5 - 3
6.6 4 1% C
4.2 4 - 5.5
6.5 1.6 - 2.5
2.6 - 4.5
(18)
Heine
. (VF) (VP)
: (VF)
VP = VF = (VC)(S/100) ( 19 )
: DP HP Heine
H P 2 .5 D P ( 20 )
:
. : VC
. : HP
. : DP

( ) ( )
( )“ ”

: (14)

(V C )( S )
DP 3 ( 21 )
196 . 35
(18)
: DR Heine
DR DP 4M C ( 22 )
: Heine

MC Heine :(15)
(18)
3MC

. (7) Heine
: (16)
DR .(9) -
.(22)
( ) -
. 1:8 1:6 1:5 :
. 5MC 4MC 2MC h -
. (Top riser) -

( ) ( )
 . (34) :(16)

Johns .
DR .
: (16)
1

DR 2 . 98 ( FW C ) 3 ( 23 )
:
.( 25.4 = 1) : DR
.( 0.45359 = 1) : WC
:F
. (18) MC Heine
(18)
(23) Johns Heine
MC DR .(17)
. WC

( ) ( )
( )“ ”

. (16) DR :(17)

(Ha) (23)
(18) .
: (Hg) .
2 .2 w g M C
Hg ( 24 )
wg 2 .2 M C
. wg

( ) ( )
 Hb :(18)
(16)
. Hs

: : ,
(steel) (Risering System)
.(19)

.( 25.4 = 1) :(19)

((Steel) Johns ):
( ) .
) ((3) (1) )
: ((2)

( ) ( )
 ( )“ ”

v1 6 6 5
M C1 0.97 in (25)
a1 4 6 5 2 6 6 5 1 .5
v2 1.5 5 10
M C2 0.57 in (26)
a2 (1.5 2 5 2) 10
v3 4 5 5
M C3 0.8 in (27)
a3 2 5 5 4 4 5 5 1 .5
MC3 MC1 MC2
(1) (2) (Two Feeding Paths)
(3) (1) .(3) (2)
.
(18) (Blind Side Riser) .
.(1)
(Open Top Riser)
.(3)
(Blind Side Riser) .
: MC(1-2) W2-1
1.5 5 10
W2 1 0.29 5 6 6 63 lb (28)
2
5 6 6 1.5 5 5
M C ( 2 1) 0.87 in (29)
4 6 5 2 6 6 5 (1.5 2 5)
.(3 / 8027 ) 0.29
(16) ( 28.6) WC = 63 MC = 0.87
.( 146) 5.75 in DR

( ) ( )
 ( 96.5) 3.8 (wg)
.( 96.5) 3.8 in (24) (Hg)
: (16)
Dg 4 .4 M C 4.4 0.87 3 .8 in (30 )

(Open top Riser) .

:

W2 3 0.29 5 5 4 1 .5 5 5 40 lb (31)
:
5 5 4 1.5 5 5
M C(2 3) 0.73 in (32)
2 5 5 4 4 5 5 (1.5 2 5)
DN . ( 122) 4.8 in DR (16)
. DR /2 ( )
((20) )
.(19)

3.8

(19) (20)

( ) ( )
 ( )“ ”

. ( )

:
" " (
.9 (1963)
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( ) ( )
19) Kura, J.G., American Foundry Man, 27, (1955), 123.
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" " (32
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