Designing for Eliminating

Defects in Aluminium Casting

Under the Guidance of:-
Mr. Amiya Kumar Sahoo

Presented By:-
Ankur Aggarwal(08604g)
Purshottam Lodha(08620g)
Satyam Pal(08623g)


1
Objective
10cm
30cm
25cm
5cm
2
10 cm

Work done so far
Overview of gating system, pattern design and
defects.
Design of pattern with allowances .
Calculation of volume, weight of casting and pouring
time.
Calculation for gating system.

3
Shrinkage allowances for various
metals
Material Pattern dimensions , mm Shrinkage Allowances
(mm/m)
Grey cast iron Up to 600 10.5
600 to 1200 8.5
Malleable iron - 11.8
Chromium steel - 20
Aluminum - 13
Aluminium bronze - 20.0 to 23.0
4
Calculations for shrinkage
allowanace
For dimension 12.5 cm,
allowances 12.5*13/1000 = 0.1625
after allowances=12.5+0.1625=12.662 cm
For dimension 10cm,
allowances 10*13/1000 = 0.13
after allowances=10+0.13=10.13cm
For dimension 2.5 cm,
allowances 2.5*13/1000 = 0.0325
after allowances=2.5 +0.0325=2.53cm





5
After Shrinkage Allowance
6
Machining Allowances on patterns
Dimension,mm Allowances,mm
Bore
Allowances,mm
Surface
Non ferrous
Up to 200 2.0 1.5
201 to 300 2.5 1.5
301 to 900 3.0 2.5
7
Calculations of machining
allowanace
For dimension 12.66 cm,
allowances 15mm or .15cm
after allowances=12.66+0.15=12.81m
For dimension 10.13cm,
allowances 1.5mm or .15cm
after allowances=10+0.15=10.28cm
For dimension 2.53cm,
allowances 1.5mm or .15cm
after allowances=2.53+0.15=2.68cm


8
After machining Allowance
9
Draft allowances
10
Pattern material Height of surface,mm Draft angle of
surfaces, degree
External surface
Draft angle of
surfaces, degree
Internal surface

wood 51 to 100 1.00 1.50
101 to 200 .75 1.00
201 to 300 .50 1
Unpressurised gating system
11
Total cross sectional area
increase towards the mould
cavity.
Flow of liquid(volume) is
different from all gates.
Less turbulence
We have selected Gating
ratio
1:3:3
(choke area : runner area: gate
area)

Calculation For weight of casting
Density of aluminium () : 2.7 g/ cm
Melting Temperature : 660.37 C
Volume of casting =5500 cm
Mass of casting = volume X density of metal used
= 5500 *2.7Kg
=14.85kg

Mass of metal poured = X 100
yield casting
mass casting actual
12
Casting yield for aluminium =25 40 (30 taken)

Mass of metal poured (W) =

W = 49.5 Kg

Pouring rate =

hence, pouring time(t)=

t = =99 sec.


time pouring
poured metal of mass
rate pouring
poured metal of mass
Pouring rate for aluminium = 0.5 kg/s (from
table)
13
Calculating the Choke Area
Choke Area =

Effective head of casting(H): h-c/2
here ht = 23 cm
c = 10.43cm
Hence , H = 17.78cm
W= casting mass
= density of molten metal
t = pouring time
C=efficiency factor
H= effective metal head
g= accel. due to gravity

gH C t
W
2
14

2

Density of aluminium = 2.7 g/cm

Efficiency factor(C) = 0.90 (from table)

Therefore ,
Choke Area =

= 330.6 cm
2


Choke diameter (dc) = 20.52 cm


( )
( )
c
A

15
Runner and Gate design
calculation:
For Aluminium casting gating ratio= 1:3:3
Runner Area = 3 X

= 3 X = 991.8 cm
2

Assuming trapezoidal cross section and w:h=1,the
runner dimension would be = 31.49 /28.41cm
(approx.).h=31.49,w=31.49 cm.
Calculating the in gate area and dimension;
gate area = 1.5 X 330.6 =495.9 cm
2

Assuming aspect ratio of 4 , (width to height ratio)
the size of gate = 11.34 cm X 44.53 cm (approx.)
4
2
c
d H
16
( )
4
29 . 12
2
H
Calculation of Sprue Area
Law of continuity (Q)= AV =AV


Velocity at inlet( V ) :










Velocity at exit of sprue ( V )









t
gh v 2
2
=
s cm
s cm
/ 65 . 21
65 . 21 23 100 81 . 9 2
=
= =
s cm
s cm
gh v
/ 045 . 99
/ 045 . 99 5 100 81 . 9 2
2
1
=
= =
=
cm h
t
23 =
17
2
1
1
05 . 707
5
23
6 . 330
cm A
h
h
A A
t
c
=
=
=
) 6 . 330 (
2
2
cm A =
cm d sprue of diameter Bottom
cm d sprue of diameter Top
52 . 20 ) (
05 . 30 ) (
2
1
=
=
18
Calculation for Riser Design
Calculation for the diameter of Riser :




Here , Area of casting = 550 cm

Volume of casting = 5500 cm

Area of Riser (cylindrical) =
riser of volume
riser of Area
casting of volume
casting of Area
= (X) ratio Freezing
2
4
2 D Dh
r
[
+ [
19
Since using Blind Riser (Height to diameter
ratio)= 1:1
means ,





D h
r
=
D
D
D
X
D h D riser of Volume
D D D riser of Area
r
0219 . 0
785 . 0
39 . 3
81 . 163100
876 . 17901
785 . 0
4
93 . 3 78 . 0 14 . 3
3
2
3 2
2 2 2
= =
=
[
=
= + =
20
By using Empirical relation for freezing Ratio :


where , a, b & c are constant
a, b & c values for Aluminium ,
a = 0.10
b = 0.06
c = 1.08

c
b Y
a
X +

=
3 4
3
10 4272 . 1
5500
785 . 0
D
D
volume casting
volume riser
Y

= = =
21
.) ( 25 . 12
.) ( 25 . 12
,
0 11264 420 49
08 . 1
06 . 0 10 427 . 1
10 . 0
0219 . 0
) (
3 4
3 4
approx cm riser of height
approx cm D
method error trialand By
D D D
D
D
X ratio f reezing
=
=
=
+

=
=

22
FINAL DIMENSIONS OF
GATING SYSTEM
1 CHOKE AREA = 330.6 cm
2 CHOKE DIAMETER = 20.52 cm
3 SPRUE UPPER DIA = 30.05 cm
4 SPRUE BOTTOM DIA = 20.52 cm
5 RUNNER WIDTH = 31.4 cm
6 VELOCITY OF SPRUE INLET = 99.045 cm/sec
7 VELOCITY OF SPRUE EXIT = 21.65 cm/sec
8 RUNNER EXTENSION =62.8 cm
23
References
http://www.mechlook.com/2010/04/pattern-and-
pattern-allowances/, date: 5 oct. 2011
http://www.brtechnocast.com/, date: 7 oct. 2011
www.2hoffshore.com/documents/papers/pap034.p
df, 2oct 2011
Malik and Ghosh, Manufacturing Science
P.N.Rao, Manufacturing Technology.
T.V Raman Rao,Metal casting.
24
THANK YOU
25