GATING SYSTEM

Gating system
Gating system refers to all channels through which molten metal
flows to enter the mould cavity.
The gating system should be such that erosion of mould or core
does not occur. It can be done by reducing the velocity of the molten
metal within the cavity and avoiding direct impingement on mould
walls or cores.
The object of any gating system is to allow the mold to be filled as
rapidly as possible with a minimum amount of turbulence and to
provide sufficient hot metal to feed the casting during solidification to
prevent shrinkage defects.
The soundness of casting depends to a large extent on the way in
which the metal enters the mould cavity and the rate of solidification.
.

FUNCTIONS OF THE GATING SYSTEM

Gating system serves the following purposes, requirements and functions.
To fill the mould cavity completely
To help in proper directional solidification
Provide means for separation of non-metal like inclusions
Regulate the rate of liquid metal flow in to the mould cavity.
Practical, economical and simple in design
Minimum amount of metal in sprue, runner. gates and risers should be
consumed because all these arc removed from the casting after
solidification and the metal is rendered waste.
In addition to the above design considerations, proper functioning of me
gating system also depends upon the following factors:
(i) Temperature of casting and fluidity of molten metal (ii) Rate of molten
metal pouring (iii) Shape and size of the sprue (iv) Shape and size of the
runner

Types of gates.
The three main types of gates are:
(1) parting, (2) top. and l3) bottom
parting gate : - between cope and drag is the easiest and fastest for
the molder to make. Its chief disadvantage is that molten metal drops
into die cavity and may cause erosion or washing of the mold. In the
case of nonferrous metals, this drop aggravates the dross and
entraps air in the metal, which makes for inferior casting.

Top gates are used for gray iron castings of simple designs, but not for
nonferrous alloys since they have a tendency to form excessive dross
when agitated. A disadvantage of top gating is that it is conducive to a
favorable temperature gradient; a big disadvantage is that of mold
erosion.

A bottom gate offers smooth flow with a minimum of mold and core
erosion. Its main disadvantage is that it creates an unfavorable
temperature gradient. The metal is introduced into the bottom of the
mold cavity and rises quietly and evenly. It cools as it rises, and the
result is a condition of cold metal and cold mold near the riser and hot
metal near the gate. The riser should contain the hottest metal in the
hottest part of the mold so it can feed metal into the mold until the
casting has solidified.

Elements of gating system

Pouring basin
The molten metal is not directly poured into the mould cavity
because it may cause mould erosion. Molten metal is poured
into a pouring cup or basin, which acts as a reservoir at the top
of the sprue from which it flows smoothly into the sprue.
When the total amount of metal poured exceeds 90 cubic
inches, it is advantage to use a pouring basin.
The best pouring basins are rectangular with a flat as opposed
to rounded bottom.
The basin should be large enough to "hit" when pouring the
molten metal and should be deep enough to prevent a vortex
from forming and drawing air into the sprue.
Two and a half inches minimum depth works well for most
smaller castings.
The basin may be formed from green sand, however they are
often made of baked sand. Pouring cups are less desirable than
basins but also used.

Pouring cup or basin rules

The following rules are used in basin design:Pouring cups, whether external or cut in the moulding
sand, is used to help separate the dross and slag from the
molten metal.
The metal must be poured into the basin at a point that is
remote from the sprue hole, to prevent vortexing and the
turbulence develop.
A pouring basin can be used to ease the filling of the
mould and also to minimize the possibility of the air and
oxide entrance into the mould cavity.
Skimmer cores filter or delay screen can be used in the
pouring basin, to help and provide cleaner metal into the
mould.

Sprue rules
The sprue is the part of gating system into which the molten metal is
poured. it is a vertical channel that connects the pouring basin with
runners and gates. The following in a list of typical rules used in sprue
design:
The sprue should be sized to limit the flow rate of the molten. If the
sprue is large, the flow rate of metal will be high.
Height of sprue is determined by casting and top riser height.
Sprue should be tapered by approximately 5% minimum to avoid
aspiration of the air and free fall of metal.
Some air is almost always carried down with the first metal that enters
the mould. This should be washed out in a well bellow the sprue.
The diameter of the well should be 2.5 time the width of the runner.
The well should be extended down bellow the runner to depth equal to
the depth of the runner .
The well should have straight sides with no sharp corners and the
bottom should be flat as possible.

Sprue base
This is a reservoir for the metal at the bottom of the sprue
to reduce the momentum of the falling molten metal.
The molten metal, as it moves down the sprue, gains in
velocity, some of which is lost in the sprue base well, and
the mould erosion is reduced.
This molten metal changes direction in the sprue base and
flows into the runner in a more uniform way.

Runner rules
Runners are the passages that carry the molten metal from the sprue
well to the gates through which the molten metal enters the mould
cavity.
The rules that are commonly used, for runner design is as follows:
The increase of cross-section area of runners from the choke area
decreases the velocity of the molten metal in the runner. There by
reducing turbulence and helping the dross to rise or sink in the
runner.
Rectangular cross-section area is preferred in sand casing.
Runners extension (blind end) is used in most casting to trap any
dross that may occur in the molten metal stream.
The runners area is three to ten time the cross-section area of
sprue exit.

Skim bob
It is an enlargement along the runner whose function is to trap heavier
and lighter impurities such as dross or eroded sand. So it prevents
these impurities from going into mould cavity.
Choke: it is that part of the gating system which has the smallest cross
sectional area. It perform the following functions: To control the rate of metal flow to help lower the velocity in the
runner.
To hold back slag and foreign material and float these in the cope
side of the runner.
To minimize sand erosion in the runner.

Gates rules.
Gates are the passage between the runner and the part. The
following rules on gate design in common practice.
Gate into thick regions
Use standard sizes, shapes for the gates. Rectangular gates are
mostly used.
The numbers of gates depend on the design of the casting and
risers.

Riser rules
Similar to the procedure used in gate design; the following rules are
extracted from foundry man practices: Risers are attached to heavy sections of casting .
Side risers are used for thin wall casting.
Top risers are allocated on bosses, away from the gates.
Risers are sized by the volume fed. In the case of multiple risers,
each riser is considered to be feeding the apart of the casting , e.g.
the total volume of the casting is divided by the number of the risers
suggested.
The connections between the risers and casting must be solidified
just after the casting solidification and just before the riser does.

Types of Gating Systems

Pressurized gating system
Un-pressurized gating system
Pressurized Gating System
The total cross sectional area decreases towards the mold cavity
Back pressure is maintained by the restrictions in the metal flow
Flow of liquid (volume) is almost equal from all gates
Back pressure helps in reducing the aspiration as the sprue always
runs full
Because of the restrictions the metal flows at high velocity leading to
more turbulence and chances of mold erosion
Un-Pressurized Gating System
The total cross sectional area increases towards the mold cavity
Restriction only at the bottom of sprue
Flow of liquid (volume) is different from all gates
aspiration in the gating system as the system never runs full
Less turbulence

FACTORS CONTROLING GATING DESIGN

The following factors must be considered while designing gating system.
Sharp corners and abrupt changes in at any section or portion in
gating system should be avoided for suppressing turbulence and gas
entrapment. Suitable relationship must exist between different crosssectional areas of gating systems.
The most important characteristics of gating system besides sprue
are the shape, location and dimensions of runners and type of flow. It
is also important to determine the position at which the molten metal
enters the mould cavity.
Gating ratio should reveal that the total cross-section of sprue,
runner and gate decreases towards the mold cavity which provides a
choke effect.
Bending of runner if any should be kept away from mold cavity.
Developing the various cross sections of gating system to nullify the
effect of turbulence or momentum of molten metal.
Streamlining or removing sharp corners at any junctions by providing
generous radius, tapering the sprue, providing radius at sprue
entrance and exit and providing a basin instead of pouring cup etc.