Useful equations

I. Gating design:
(1) For Grey CI mass less than 450 kg
𝑇
Pouring time, t (sec) = K (1.41 + 14.59) √𝑊

K = Fluidity of iron in inches/40; T = average section thickness, mm, W = mass of the casting (kg)

(2) Grey CI, mass greater than 450 kg

𝑇 3
Pouring time, t (sec) = K (1.236 + 16.65) √𝑊

Choke area: W/ρtCd√2𝑔𝐻

H = h (Top gate); H = h- c/2 (Bottom gate); H = h- p2/2c (Parting gate)

Freezing ratio, X = (A/V)casting / (A/V)riser

𝑎
Caine’s equation: X = 𝑌−𝑏 + 𝑐; Y = riser volume/casting volume; a, b and c are constants

II. Effects of friction and velocity distribution:

𝐿 𝑣̅ 2
Darcy-Weisbach equation: Ef1 = 4 f (𝐷) ( 2 )

f = 16/Re for laminar flow; f = 0.0791 (Re)-0.25 for turbulent flow

Friction loss due to sudden enlargement: Ef2 = 0.5𝑒𝑓 𝑣̅ 2

1
III. Solidification:
(𝑉/𝐴) (𝜃𝑓 − 𝜃0 ) 𝜌𝐶
β = ;λ= ; L` = L + Cm (θp – θf)
√𝛼𝑡 𝜌𝑚 𝐿`

2 2 1 2 1
β=λ (for an infinite plane); β = λ [ + ] (for a sphere); β = λ [ + ] (for a long
√𝜋 √ 𝜋 3𝛽 √ 𝜋 4𝛽
cylinder)

Solidification with predominant thermal resistance in mold:

𝑥
θ = θ0 + (θf – θ0) [1 – erf(2 )]
√𝛼𝑡

Solidification with predominant thermal resistance in solid casting:

(𝜃− 𝜃𝑠 ) 𝑥
= erf (2 )
(𝜃𝛼 − 𝜃𝑠 ) √𝛼𝑠 𝑡

Solidification with predominant thermal resistance in both mold and solid casting:

Assuming semi-infinite medium in the negative X direction.

(𝜃− 𝜃𝑠 ) −𝑥
= erf (2 ) for x<0
(𝜃0 − 𝜃𝑠 ) √𝛼𝑠 𝑡

(𝜃− 𝜃𝑠 ) 𝑥
= erf (2 ) for x>0
(𝜃𝛼 − 𝜃𝑠 ) √𝛼𝑠 𝑡