Impact of Sprue Base in Gating System on Quality of Filling – the Compromise Between Theory and Practice

• Autorzy: Siodmok B. , Jezierski J. R. , Dorula J. , Romelczyk R.

Identyfikatory

DOI

10.24425/123620

• Języki publikacji: EN

Abstrakty

EN

Foundry technologists use their own style of gating system designing. Most of their patterns are caused by experience. The designs differ from plant to plant and give better or worse results. This shows that the theory of gating systems is not brought into general use sufficiently and therefore not applied in practise very often. Hence, this paper describes the theory and practical development of one part of gating systems - sprue base for automated horizontal moulding lines used for iron castings. Different geometries of sprue bases with gating system and casting were drawn in Solid Edge ST9. The metal flow through the gating systems was then simulated with use of MAGMA Express 5.3.1.0, and the results were achieved. The quality of flow was considered in a few categories: splashes, air entrapment, vortex generation and air contact. The economical aspect (weight of runner) was also taken under consideration. After quantitative evaluation, the best shape was chosen and optimised in other simulations with special attention on its impact on filling velocity and mould erosion. This design (a sprue base with notch placed in drag and cope) is recommended to be used in mass production iron foundries to reduce oxide creation in liquid metal and especially to still metal stream to improve filtration.

Słowa kluczowe

EN

casting defects; gating system; simulation; filtration

PL

wady odlewu; układ wlewowy; symulacja

• Wydawca: Komisja Odlewnictwa Polskiej Akademii Nauk Oddział w Katowicach
• Czasopismo: Archives of Foundry Engineering
• Rocznik: 2018
• Tom: Vol. 18, iss. 3
• Strony: 167--172
• Opis fizyczny: Bibliogr. 21 poz., rys., tab.

Twórcy

autor

Siodmok B.

• Vesuvius Poland Sp. z o.o. Zakład Foseco w Gliwicach, Gliwice, Poland
• Silesian Univesity of Technology, Department of Foundry Engineering, Gliwice, Poland

autor

Jezierski J. R.

• Vesuvius Poland Sp. z o.o. Zakład Foseco w Gliwicach, Gliwice, Poland

autor

Dorula J.

• Silesian University of Technology, Department of Foundry Engineering, Gliwice, Poland

autor

Romelczyk R.

• Vesuvius Poland Sp. z o.o. Zakład Foseco w Gliwicach, Gliwice, Poland
• Silesian University of Technology, Department of Foundry Engineering, Gliwice, Poland

Bibliografia

• [1] Sobczak, J.J. et al. (2013). Contemporary casting. Guide to the founder. Volume 1 - Materials. Kraków: Wydaw. Stowarzyszenia Technicznego Odlewników Polskich. (in Polish).
• [2] Perzyk, M., Waszkiewicz, S., Kaczorowski, M., Jopkiewicz, A. (2014). Foundry. Warszawa: WNT. (in Polish).
• [3] Szałkowski, Z. et al. (1978). Engineer's guide. Foundry. Warszawa: WNT. (in Polish).
• [4] Brown, J.R. (2000). Foseco ferrous foundryman’s handbook. Oxford: Elsevier Butterworth-Heinemann.
• [5] Borowiecki, B., Borowiecka, O. & Szkodzińska, E. (2011). Casting defects analysis by the Pareto method. Archives of Foundry Engineering. 11(3), 33-36.
• [6] Borowiecki, B. (1994). Structure of the gray wall layer of the gray cast iron in the channels of the infusion system of sandy forms. Solidification of Metals and Alloys. 19, 69-76. (in Polish).
• [7] Borowiecki, B. (1998). Development of the formula of the flow coefficient of cast iron flow in the pouring system. Solidification of Metals and Alloys. 36, 71-77.
• [8] Borowiecki, B. & Ignaszak, Z. (2008). The identification of pouring conditions of cast iron to sand moulds. Archives of Foundry Engineering. 8(1), 19-22.
• [9] Jacobs, M.J. (2003). Filters: the hows & whys. (Casting facts). Modern Casting. May 2003. American Foundry Society Inc.
• [10] Roučka, J., Šenberger, J. & Veverka A. (2003). Study of metal flow through ceramic foam filters. Archives of Foundry. 3(10), 146-154.
• [11] Hawranek, R., Lelito, J., Suchy, J.S. & Żak, P. (2009). The simulation of a liquid cast iron flow through the gating system with filter. Archives of Metallurgy and Materials. 54(2), 351-358.
• [12] Nazari, E., Razavi, S.H. & Boutorabi, S.M.A. (2010). Effect of filtration on the morphology and mechanical properties of Mg molten alloy entering the mould cavity. Journal of Materials Processing Technology. 210, 461-465.
• [13] Bydałek, A. (1998). On the mechanism of filling the casting mold with liquid metal. Solidification of Metals and Alloys. 37, 31-40. (in Polish).
• [14] Li, D.Z., Campbell, J. & Lia, Y.Y. (2004). Filling system for investment cast Ni-base turbine blades. Journal of Materials Processing Technology. 148, 310-316.
• [15] Sun, Z., Hu, H. & Chen, X. (2008). Numerical optimization of gating system parameters for a magnesium alloy casting with multiple performance characteristics. Journal of Materials Processing Technology. 199, 256-264.
• [16] Kermanpur, A., Mahmoudi, Sh. & Hajipour, A. (2008). Numerical simulation of metal flow and solidification in the multi-cavity casting moulds of automotive components. Journal of Materials Processing Technology. 206, 62-68.
• [17] Hsu, F.Y., Jolly, M.R. & Campbell, J. (2009). A multiple-gate runner system for gravity casting. Journal of Materials Processing Technology. 209, 5736-5750.
• [18] Li, Q. (2015). Three dimensional numerical simulation of melt filling process in mold cavity with insets. 7th International Conference on Fluid Mechanics, ICFM7. In Procedia Engineering. 126, 496-501.
• [19] Zhang, L., Belblidia, F., Davies, H.M., Lavery, N.P., Brown, S.G.R., Davies, D. (2017). Optimizing gate location to reduce metal wastage: Co–Cr–W alloy filling simulation. Journal of Materials Processing Technology. 240, 249-254.
• [20] Tuttle, R.B. (2012). Foundry engineering. The metallurgy and design of castings. Saginaw Valley State University.
• [21] Campbell, J. (2015). Complete casting handbook. Metal casting processes, Metallurgy, Techniques and Design. (2nd ed.). Oxford: Butterworth-Heinemann.

Uwagi

PL

Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2018).